403 404 Assembly

SENR9973
November 2004
Disassembly and
Assembly
400 Engine
HB11-Up (Machine)
HD11-Up (Machine)
HH11-Up (Machine)
HL11-Up (Machine)
HN11-Up (Machine)
HP11-Up (Machine)
HR11-Up (Machine)
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
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 have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR9973 3
Table of Contents
Table of Contents Connecting Rod Bearings - Install ........................ 75

Crankshaft Main Bearings - Remove .................... 76
Crankshaft Main Bearings - Install ........................ 77
Crankshaft - Remove ............................................ 78
Disassembly and Assembly Section Crankshaft - Install ................................................ 80
Bearing Clearance - Check ................................... 81
Fuel Priming Pump - Remove ................................. 4
Coolant Temperature Switch - Remove and
Fuel Priming Pump - Install ..................................... 4
Install ................................................................... 82
Fuel Filter Base - Remove ..................................... 5
Engine Oil Pressure Switch - Remove and Install
Fuel Filter Base - Install ......................................... 6
............................................................................. 84
Fuel Injection Lines - Remove and Install .............. 7
Glow Plugs - Remove and Install ......................... 86
Fuel Shutoff Solenoid - Remove and Install .......... 9
V-Belts - Remove and Install ................................ 86
Fuel Injection Pump - Remove ............................ 10
Fan - Remove and Install ..................................... 87
Fuel Injection Pump - Install ................................. 11
Alternator - Remove and Install ........................... 91
Fuel Injector - Remove ........................................ 12
Electric Starting Motor - Remove and Install ..... 101
Fuel Injector - Install ............................................ 12
Turbocharger - Remove and Install ..................... 13
Exhaust Manifold - Remove and Install ............... 15 Index Section
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 17 Index ................................................................... 103
Inlet and Exhaust Valves - Remove and Install .... 19
Engine Oil Line - Remove and Install ................... 21
Engine Oil Cooler - Remove and Install ............... 23
Engine Oil Relief Valve - Remove and Install ....... 24
Engine Oil Pump - Remove .................................. 24
Engine Oil Pump - Install ...................................... 26
Water Pump - Remove ......................................... 28
Water Pump - Install ............................................. 29
Water Temperature Regulator Housing - Remove and
Install .................................................................. 31
Water Temperature Regulator - Remove and Install
............................................................................. 32
Flywheel - Remove ............................................... 34
Flywheel - Install ................................................... 35
Crankshaft Rear Seal - Remove ........................... 36
Crankshaft Rear Seal - Install ............................... 37
Flywheel Housing - Remove and Install .............. 39
Crankshaft Pulley - Remove and Install ............... 42
Crankshaft Front Seal - Remove .......................... 43
Crankshaft Front Seal - Install .............................. 43
Housing (Front) - Remove .................................... 44
Housing (Front) - Disassemble ............................. 45
Housing (Front) - Assemble .................................. 47
Housing (Front) - Install ........................................ 50
Crankcase Breather - Remove and Install ........... 51
Valve Mechanism Cover - Remove and Install ..... 54
Rocker Shaft and Pushrod - Remove ................... 55
Rocker Shaft - Disassemble ................................ 56
Rocker Shaft - Assemble ..................................... 57
Rocker Shaft and Pushrod - Install ....................... 59
Cylinder Head - Remove ...................................... 60
Cylinder Head - Install .......................................... 61
Lifter Group - Remove and Install ......................... 63
Camshaft - Remove .............................................. 64
Camshaft - Disassemble ....................................... 65
Camshaft - Assemble ........................................... 66
Camshaft - Install .................................................. 66
Engine Oil Pan - Remove and Install ................... 67
Pistons and Connecting Rods - Remove .............. 68
Pistons and Connecting Rods - Disassemble ....... 69
Pistons and Connecting Rods - Assemble ........... 71
Pistons and Connecting Rods - Install .................. 73
Connecting Rod Bearings - Remove .................... 74
4 SENR9973
Disassembly and Assembly Section
Disassembly and Assembly 2. Install suitable plugs into the fuel lines in order to
prevent contamination.
Section
3. Remove the two setscrews (4) that fasten the fuel
priming pump (1) to the cylinder block.
i02186288
Fuel Priming Pump - Remove Note: The fuel priming pump can be oriented in two
positions. Before removing the fuel priming pump (1)
from the cylinder block, note the orientation of the
flange (2) of the fuel priming pump (1) for assembly.
Removal Procedure 4. Remove the fuel priming pump (1) and the O-ring
(3). Discard the O-ring.
NOTICE
Keep all parts clean from contaminants. Note: In order to remove the fuel priming pump
from the engine, it may be necessary to rotate the
Contaminants may cause rapid wear and shortened crankshaft until the operating plunger of the fuel
component life. priming pump is not under pressure.
i02186279
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Fuel Priming Pump - Install
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids. Installation Procedure
Dispose of all fluids according to local regulations and NOTICE
mandates. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

component life.
NOTICE
ponent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
g00824616
Illustration 1
Typical example
1. Loosen the hose clamps and remove the two fuel

lines from the fuel priming pump (1). Note the
positions of the fuel inlet and the fuel outlet for
installation.
SENR9973 5
i02186242
Fuel Filter Base - Remove
Removal Procedure
NOTICE
Keep all parts clean from contaminants.

component life.
NOTICE
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
g01129954
Illustration 2 nent containing fluids.
Typical example
1. Clean the mating surfaces of the fuel priming mandates.
pump on the cylinder block and clean the flange
(2) of the fuel priming pump.
Note: Ensure that the camshaft lobe for the fuel

priming pump is at minimum lobe lift before the fuel
priming pump is installed. The fuel priming pump
can be oriented in two positions. Ensure that the fuel
priming pump is oriented in the correct position.
2. Install a new O-ring (3) to the fuel priming pump(1).
3. Lubricate the operating plunger of the fuel priming

pump (1) with clean engine oil.
4. Install the fuel priming pump (1) to the engine.

Ensure that the operating plunger is positioned
correctly on the camshaft lobe.
5. Install the two setscrews (4) that fasten the fuel

priming pump (1) to the cylinder block. Tighten the
setscrews to a torque of 6 N·m (4.5 lb ft).
6. Loosely install the hose clamps to the fuel lines.

Connect the appropriate fuel lines to the fuel inlet
and the fuel outlet of the fuel priming pump (1).
Tighten the hose clamps.
Note: The fuel inlet for the fuel priming can be

rotated 360 degrees by loosening setscrew (5). The g01118406
Illustration 3
fuel inlet is adjustable in 15 degree increments. If Typical example
adjustment is made to the position of the fuel inlet,
tighten setscrew (5) to a torque of 2.5 N·m (22 lb in). 1. Disconnect the fuel lines (1) and (2). Inspect the
condition of the rubber olives (not shown) that seal
7. Prime the fuel system. Refer to Testing and the fuel lines. If the olives are damaged or worn,
Adjusting, “Fuel System - Prime” for additional use new parts for replacement.
information.
6 SENR9973
Note: Put identification marks on all the fuel lines for

installation purposes. Plug all the fuel lines and all
the ports in the fuel filter base. This helps prevent
fluid loss, and this helps to keep contaminants from
entering the system.
2. Remove the fuel filter element (4). Refer to

Operations and Maintenance Manual, “Fuel
System Filter - Replace”.
3. If necessary, remove the plugs (5), the washers

(6) and the inner seals (7).
4. Remove the setscrews (8) and the nuts (not

shown).
5. Remove the fuel filter base (3) from the engine.
i02186227
Fuel Filter Base - Install
Installation Procedure
NOTICE g01118406
Keep all parts clean from contaminants. Illustration 4
Typical example
component life. 1. Align the fuel filter base (3) with the mounting
bracket. Install the bolts (8) and nuts (not shown).
Tighten the nuts to a torque of 22 N·m (16.2 lb ft).
Note: Some fuel filters are installed by the OEM and

torques for the mounting fasteners may vary. Check
with the OEM Installation Manual for the correct
torque setting.
2. If necessary, install the fuel filter element (4)

to the fuel filter base (3). Refer to Operations
and Maintenance Manual, “Fuel System Filter -
Replace”.
3. If necessary, install new olives onto the fuel lines.

Connect the fuel lines (1) and (2) to the fuel filter
base (3). Tighten the nuts on the fuel lines (1) and
(2) to a torque of 9 N·m (6.6 lb ft).
4. If necessary, install new inner seals (7) to the fuel

filter base (3).
Install new washers (6) onto the plugs (5) and

install the plugs (5) to the fuel filter base (3).
Tighten the plugs (5) to a torque of 22.5 N·m
(16.6 lb ft).
SENR9973 7
End By:
a. Remove the air from the fuel system. Refer to

Operations and Maintenance Manual, “Fuel
System - Prime”.
i02180237
Fuel Injection Lines - Remove

and Install
Removal Procedure
NOTICE

component life. g00818680
Illustration 5
404C-22 and 404C-22T engines
NOTICE
Care must be taken to ensure that fluids are contained 1. Disconnect the union nuts (1) for the fuel injection
during performance of inspection, maintenance, test- lines (2) from the fuel injectors.
to collect the fluid with suitable containers before 2. Disconnect the union nuts (1) for the fuel injection
opening any compartment or disassembling any com- lines (2) from the fuel injection pump.
3. Remove the fuel injection lines (2) from the engine
Dispose of all fluids according to local regulations and as a unit.
mandates.
Note: Place identification marks on all tube
assemblies for installation. Plug all tube assemblies
NOTICE in order to prevent contamination.
Do not let the tops of fuel injectors turn when the fuel
line nuts are loosened or tightened. 4. Install suitable plastic plugs to the outlet
connections of the fuel injection pump.
The nozzles will be damaged if the top of the injector
turns in the body. 5. The 403C-15, 404C-22 and 404C-22T engines
have a rigid fuel return line.
The engine will be damaged if a defective fuel injector
is used because the shape of fuel (spray pattern) that For engines with a rigid fuel return line, remove
comes out of the nozzle will not be correct. the banjo bolt (4) from the fuel return line (3).
Remove the washers (8) from the fuel return line
Note: The removal procedure is similar for the two (3). Discard the washers.
cylinder, the three cylinder and the four cylinder
engines. The illustrations show the 404C-22 and The 402C-05, 403C-07, 403C-11 and 404C-15
404C-22T engines. engines have a flexible fuel return hose.
For engines with a flexible fuel return hose,

disconnect the union nut from the banjo piece.
8 SENR9973
Note: The installation procedure is similar for the

two cylinder, the three cylinder and the four cylinder
engines. The illustrations show the 404C-22 and
404C-22T engines.
g00824793
Illustration 6
404C-22 and 404C-22T engines
6. Remove the nut (5) from the fuel injectors (7).

g00824793
Illustration 7
7. Remove the fuel return line (3) from the engine 404C-22 and 404C-22T engines
and remove washers (6) from the fuel injectors
(7). Discard the washers. 1. Remove the plastic plugs from the fuel injectors
(7). Install new washers (6) to the fuel injectors
8. Install suitable plastic plugs to the fuel injectors. (7) and install the fuel return line (3) to the fuel
injectors.
Note: The washers (6) have two small holes.
NOTICE
2. Install the nuts (5) to the fuel injectors (7).
3. The 403C-15, 404C-22 and 404C-22T engines
have a rigid fuel return line.
component life.
For engines with a rigid fuel return line, install new
NOTICE washers (8) to the fuel return line (3) and install the
Do not let the tops of fuel injectors turn when the fuel banjo bolt (4) to the fuel injection pump. Tighten
line nuts are loosened or tightened. the banjo bolt (4) to a torque of 7 N·m (5.2 lb ft).
The nozzles will be damaged if the top of the injector The 402C-05, 403C-07, 403C-11 and 404C-15
turns in the body. engines have a flexible fuel return hose.
The engine will be damaged if a defective fuel injector For engines with a flexible fuel return hose,
is used because the shape of fuel (spray pattern) that connect the fuel return hose to the banjo piece
comes out of the nozzle will not be correct. and tighten the union nut.
4. Tighten the nuts (5) to a torque of 27 N·m (20 lb ft).

SENR9973 9
i02207974
Fuel Shutoff Solenoid -

Remove and Install
Removal Procedure
NOTICE

component life.
NOTICE
g00818680 to collect the fluid with suitable containers before
Illustration 8
404C-22 and 404C-22T engines ponent containing fluids.
5. Remove the plastic plugs from the fuel injection Dispose of all fluids according to local regulations and
lines (2) and remove the plastic plugs from the mandates.
outlet connections of the fuel injection pump.
Install the fuel injection lines to the engine as a
unit.
6. Connect the fuel injection lines (2) to the fuel

injection pump.
7. Connect the fuel injection lines (2) to the fuel

injectors (7).
8. For the 402C-05 and 403C-07 engines, tighten

the union nuts (1) to a torque of 20 N·m (15 lb ft).
For the 403C-11, 403C-15, 404C-15, 404C-22

and 404C-22T engines, tighten the union nuts (1)
to a torque of 23 N·m (17 lb ft). g00824952
Illustration 9
9. Prime the fuel system. Refer to Testing and

1. Disconnect electrical connections (3) to the fuel
Adjusting, “Fuel System - Prime” for more
shutoff solenoid (1). Mark all connections for later
information.
installation.
Note: If new fuel injection lines have been installed,
2. Remove fuel shutoff solenoid (1) from the fuel
do not make any adjustments to the engine controls.
injection pump housing by rotating the fuel shutoff
Check the maximum engine speed at no load. Refer
solenoid in a counterclockwise direction.
to Testing and Adjusting, “Engine Speed - Check”
for more information.
3. Remove the O-ring (2) from fuel shutoff solenoid
(1).
NOTICE

component life.
10 SENR9973
NOTICE

mandates.
Note: The removal procedure is similar for the two

g00824952 engines. The illustrations show the four cylinder
Illustration 10
engine.
1. Check the condition of O-ring (2). If the O-ring is
worn or damaged use a new part for replacement.
2. Install fuel shutoff solenoid (1) into the fuel

injection pump housing by rotating the fuel shutoff
solenoid in a clockwise direction. Tighten the fuel
shutoff solenoid to a torque of 17.5 N·m (12.9 lb ft).
3. Reconnect electrical connection (3) to fuel shutoff

solenoid (1) before you operate the engine.
i02181224
Fuel Injection Pump - Remove

g00825132
Illustration 11
Typical example
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to

Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.
b. Remove the fuel shutoff solenoid. Refer to

Disassembly and Assembly, “Fuel Shutoff
Solenoid - Remove and Install”.
NOTICE
g00825137
Illustration 12
Contaminants may cause rapid wear and shortened Typical example
component life.
1. Remove the setscrews (4) and the nuts (2) that
fasten the fuel injection pump to the cylinder block.
2. Carefully raise the fuel injection pump (1) from

the cylinder block and remove the clip (7) that
connects the link (6) to the fuel rack control (5).
3. Remove the fuel injection pump (1) from the

cylinder block.
SENR9973 11
4. Remove the shims (3) from the mounting face of 2. Install the correct thickness and the correct
the cylinder block. number of shims (3) on the mounting face of
the cylinder block. Refer to Specifications, “Fuel
Note: Record the thickness of each shim and the Injection Pump”.
number of shims for reassembly. The fuel injection
timing is determined by the thickness of the shim
pack that is between the fuel injection pump and
the mounting face on the cylinder block. For more
information on the fuel injection pump, refer to
Specifications, “Fuel Injection Pump”.
i02181267
Fuel Injection Pump - Install
g00825137
Illustration 14
NOTICE Typical example
3. Position the fuel injection pump (1) close to the
Contaminants may cause rapid wear and shortened mounting face of the cylinder block, and connect
component life. the link (6) and the fuel rack control (5) with the
clip (7).
NOTICE 4. Put the fuel injection pump (1) in position on the
Care must be taken to ensure that fluids are contained mounting face of the cylinder block.
ing, adjusting, and repair of the product. Be prepared 5. Install the setscrews (4) and the nuts (2) that
to collect the fluid with suitable containers before fasten the fuel injection pump to the cylinder block.
ponent containing fluids. For 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the setscrews (4) and the nuts (2)
Dispose of all fluids according to local regulations and to a torque of 6 N·m (53 lb in).
mandates.
For 403C-15, 404C-22 engines and 404C-22T
Note: The installation procedure is similar for the engines, tighten the setscrews (4) and the nuts (2)
two cylinder, the three cylinder and the four cylinder to a torque of 15 N·m (11 lb ft).
engines. The illustrations show the four cylinder
engine. End By:
1. Clean the mounting face of the fuel injection pump a. Install the fuel shutoff solenoid. Refer to
on the cylinder block. Clean the mating surface of Disassembly and Assembly, “Fuel Shutoff
the fuel injection pump. Solenoid - Remove and Install”.
b. Install the fuel injection lines. Refer to Disassembly

and Assembly, “Fuel Injection Lines - Remove
and Install”.
g00825132
Illustration 13
Typical example
12 SENR9973
i02186247 Note: 402C-05 and 403C-07 engines have two seat

washers. The seat washers are different diameters.
Fuel Injector - Remove 403C-11, 403C-15, 404C-15, 404C-22 and 404C-22T
engines have one seat washer.
3. Cap all openings or plug all openings immediately

Removal Procedure after disassembly.
Start By:
i02186246
a. Remove the fuel injection lines. Refer to Fuel Injector - Install

NOTICE Installation Procedure

Contaminants may cause rapid wear and shortened NOTICE

component life. Keep all parts clean from contaminants.

NOTICE component life.

mandates.
g01113718
Illustration 16
Typical example
1. Clean the injector bore in the cylinder head.

Ensure that no debris enters the cylinder head.
Clean the threads on the body of the injector.
2. Install new seat washers (3) into the injector bore

in the cylinder head.
g01124706
Illustration 15
Typical example Note: 402C-05 and 403C-07 engines have two seat
washers. The seat washers are different diameters.
1. Use a deep socket to remove the fuel injector (1) 403C-11, 403C-15, 404C-15, 404C-22 and 404C-22T
from the cylinder head. engines have one seat washer.
2. Remove the seat washers (2) from the cylinder

head. Discard the old seat washers.
SENR9973 13
3. Apply a bead of 1861117 POWERPART

Universal Jointing Compound (2) to the first two
threads of the injector that engage into the cylinder
head. The bead of Universal Jointing Compound
should have a diameter of 2 mm (0.08 inch) and a
length of 6 mm (0.25 inch).
Note: Ensure that the universal jointing compound

does not cover the surface of the fuel injector body
below the threads.
4. Install the fuel injector (1) into the cylinder head.

Use a deep socket to tighten the fuel injector to a
torque of 64 N·m (47 lb ft).
Note: If a new fuel injector has been installed, do not

make any adjustments to the engine controls. Refer
to Testing and Adjusting, “Engine Speed - Check”
for more information.
End By:
a. Install the fuel injection lines. Refer to Disassembly

and Assembly, “Fuel Injection Lines - Remove
and Install”.
i02186260
g01114005
Turbocharger - Remove and Illustration 17
Install 1. Clean the outer surfaces of the turbocharger (1).
2. Loosen the hose clamps (4). Remove the air inlet

hose (5).
Removal procedure
NOTICE

component life.
NOTICE

mandates.
g01114003
Illustration 18
3. Remove the exhaust pipe (not shown) from the

exhaust elbow (21). Refer to the OEM provided
information for the correct procedure in order to
remove the exhaust pipe.
14 SENR9973
4. Remove the setscrews (15) and remove the 1. Remove all of the plastic plugs from all of the ports
support bracket for the turbocharger (16). Note of the turbocharger (1). Clean the mating surfaces
the position of the support bracket for installation. of the exhaust manifold and the turbocharger.
5. Remove the setscrews (22). Remove the exhaust

elbow (21) from the turbocharger (1). Remove
the gasket for the exhaust elbow (20) from the
turbocharger. Discard the gasket.
6. Place a suitable container below the turbocharger

(1) in order to collect any spillage of oil.
7. Remove the banjo bolt (3). Remove the oil supply

tube assembly (8). Remove the washers (2)
from the turbocharger. Discard the washers. If
necessary, remove the setscrews (not shown)
for the tube clips (6). Remove the setscrews (7).
Remove the oil supply tube assembly (8) from the
cylinder block. Remove the O-ring (9). Discard
the O-ring.
8. Remove the setscrews (13). Remove the oil

drain tube assembly (11) from the turbocharger.
Remove the joint (14) and discard the joint. If
necessary, remove the setscrews (12) and remove g01114003
Illustration 19
the oil drain tube assembly (11) from the cylinder
block. Remove the joint (10). Discard the joint.
2. Ensure that all of the turbocharger inlet and outlet
ports are clean and free from restrictions. The
9. Remove the nuts (19) and the washers (18).
turbocharger shaft must rotate freely.
Remove the turbocharger (1) from the exhaust
manifold. Remove the turbocharger gasket (23)
3. If the studs (17) were previously removed, install
from the exhaust manifold. Discard the gasket.
the studs into the exhaust manifold. Install a new
If necessary, remove the studs (17) from the
gasket (23) over the studs (17).
exhaust manifold.
Note: Do not use any sealant on the gasket (23).
Note: Do not use the actuator rod of the wastegate
to lift the turbocharger.
Note: Do not use the actuator rod of the wastegate
to lift the turbocharger (1).
10. Inspect the turbocharger for damage. If the
turbocharger is damaged use a new part for
4. Position the turbocharger (1) onto the exhaust
replacement. Refer to Testing and Adjusting,
manifold.
“Wastegate - Test”.
5. Install the washers (18) and install the nuts (19).
11. Install suitable plastic plugs into the oil supply
Tighten the nuts to a torque of 25 N·m (18 lb ft).
and into the oil drain ports of the turbocharger (1).
Install suitable plastic covers to the inlet and to the
6. Lubricate the bearing housing of the turbocharger
outlet of the turbocharger. Install suitable plastic
(1) with clean engine oil. Apply the lubricant
plugs to the oil supply tube assembly (8) and to
through the oil supply port (24).
the oil drain tube assembly (11).
Installation procedure
NOTICE

component life.
SENR9973 15
13. Clean the mating surfaces of the exhaust elbow

(21). Position a new gasket (20) and the exhaust
elbow (21) on the turbocharger (1). Install the
setscrews (22). Tighten the setscrews to a torque
of 32 N·m (24 lb ft).
14. Install the set screws (15) and install the support
bracket for the turbocharger (16). Tighten the
setscrews to a torque of 25 N·m (18 lb ft).
15. Ensure that the inlet hose (5) is clean and free
from defects or restrictions. Loosely install the
hose clamps (4) to the air inlet hose (5). Install
the air inlet hose to the connection of the inlet
manifold and to the inlet of the turbocharger.
Tighten the hose clamps.
Note: Do not use oil or grease in order to install the

air inlet hose. In order to install a new air inlet hose,
lubricate the connection of the inlet manifold and
lubricate the inlet of the turbocharger with a solution
of water and 5% soap.
16. Position the exhaust pipe onto the exhaust elbow

(21). Refer to the OEM information for the correct
procedure in order to install the exhaust pipe.
g01114005 i02186310
Illustration 20
7. Clean the oil supply tube assembly (8) and the oil
Exhaust Manifold - Remove
drain tube assembly (11). Inspect the oil supply and Install
tube assembly and the oil drain tube assembly. If
necessary, replace the tube assemblies.
8. Position a new joint (14) and the oil drain tube

assembly (11) onto the bottom of the turbocharger.
Removal Procedure
Install the setscrews (13). Tighten the setscrews
to a torque of 10 N·m (7 lb ft). NOTICE
9. If necessary, position a new joint (10) and the oil
drain tube assembly (11) onto the cylinder block. Contaminants may cause rapid wear and shortened
Install the setscrews (12). Tighten the setscrews component life.
to a torque of 10 N·m (7 lb ft).
Note: The two cylinder, the three cylinder and the four
10. Position the new washers (2) and the oil supply cylinder engines have different exhaust manifolds.
tube assembly (8) onto the turbocharger (1). The removal procedure is similar for all models.
Install the banjo bolt (3). Tighten the banjo bolt to
a torque of 18 N·m (13 lb ft).
11. If necessary, install a new O-ring (9) and the oil

supply tube assembly (8) to the cylinder block.
Install the setscrews (7). Tighten the setscrews to
a torque of 10 N·m (7 lb ft).
12. If necessary, install the spacer (not shown) and

install the setscrews (not shown) to the tube clips
(6). Torque the setscrews to 10 N·m (7 lb ft).
Note: Ensure that the oil supply tube assembly (8)

does not come into contact with any other component
when the assembly is installed onto the engine.
16 SENR9973
g00825291 g00825291
Illustration 21 Illustration 22
Typical example Typical example
1. Loosen the nuts (5) and the setscrews (6). 1. If necessary, install the exhaust manifold studs
(2) to cylinder head (1).
Note: In order to prevent distortion of the exhaust
manifold, loosen the outer fasteners first. 2. Install a new exhaust manifold gasket (3) to the
cylinder head (1).
2. Remove the nuts (5) and the setscrews (6).
Note: Do not use any sealant on the exhaust
Note: Identify setscrews of different lengths so manifold gasket.
that the setscrews can be reinstalled in the correct
positions. 3. Put the exhaust manifold (4) in position on the
cylinder head (1).
3. Remove the exhaust manifold (4) from the cylinder
head (1). 4. Install the nuts (5) and the setscrews (6).
4. Remove the gasket (3) from the cylinder head. Note: Ensure that setscrews with different lengths
are installed in the correct holes.
5. Remove any remaining gasket material and
carbon from the cylinder head and the exhaust 5. For 402C-05, 403C-07, 403C-11 and 404C-15
manifold. Be careful not to damage the mating engines, tighten the nuts (5) and the setscrews (6)
surface on the cylinder head or the mating surface to a torque of 10 N·m (89 lb in).
on the exhaust manifold.
For 403C-15, 404C-22 and 404C-22T engines,
6. If necessary, remove the exhaust manifold studs tighten the nuts (5) and the setscrews (6) to a
(2) from the cylinder head (1). torque of 25 N·m (18 lb ft).
Note: On three cylinder engines, tighten the two inner

Installation Procedure setscrews first. On four cylinder engines, tighten the
four inner setscrews first. Then tighten the two outer
NOTICE setscrews and the two nuts.

component life.
cylinder engines have different exhaust manifolds.
The installation procedure is similar for all models.
SENR9973 17
i02187986
NOTICE
Inlet and Exhaust Valve Install suitable plugs to the inlet ports of the cylinder
Springs - Remove and Install head in order to prevent the entry of loose parts into
the engine.
Removal Procedure
Table 1
Required Tools
Part Number Part Description Qty
21825666 Valve Spring Compressor 1
27610235 Adapter 1
Start By:
a. Remove the rocker shaft assembly. Refer to g01015085

Illustration 23
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”. Typical example
1. Use the following procedure in order to find the

NOTICE
top dead center position of the appropriate piston.
a. Install 21825666 Valve Spring Compressor
(1) and the appropriate 27610235 Adapter
component life.
(2) in position on the cylinder head in order to
compress the appropriate valve spring (5).
Note: Before you begin the removal of the valve
springs, refer to Specifications, “Cylinder Head - b. Compress the valve spring (5) sufficiently in
Valves” and Testing and Adjusting, “Cylinder Head order to open the valve only. Do not compress
- Inspect” for appropriate information on the valve the valve spring so that the valve keepers (3)
springs. could be removed from the recess in the valve
stem or so that the valve stem seal (not shown)
Note: The following procedure should be adopted could be damaged.
in order to remove the valve springs when the
cylinder head is still installed onto the cylinder block. c. Slowly turn the crankshaft until the piston
Refer to Disassembly and Assembly, “Inlet and touches the valve.
Exhaust Valves - Remove and Install” for the correct
procedure that should be used to remove the valve d. Continue to turn the crankshaft and release the
springs from a cylinder head that has been removed pressure on the valve spring compressor (1)
from the cylinder block. until the piston is at the top center position.
Note: Ensure that the appropriate piston is at top NOTICE

dead center before the valve spring is removed. Ensure that the valve spring is compressed squarely
Failure to ensure that the piston is at top dead center or damage to the valve stem may occur.
may allow the valve to drop into the cylinder bore.
Note: If you are replacing all of the valve springs,

on four cylinder engines only, the procedure can
be done on two cylinders at the same time. The
Personal injury can result from being struck by procedure can be done on cylinder 1 and cylinder 4,
parts propelled by a released spring force. or on cylinder 2 and cylinder 3. Remember that the
crankshaft must not be turned while the valve springs
Make sure to wear all necessary protective equip- are removed. Ensure that all of the valve springs are
ment. installed before changing from one pair of cylinders
to the other pair of cylinders.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
18 SENR9973
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
2. Use the valve spring compressor (1) and the

adapter (2) in order to compress the valve spring
(5). Remove the valve keepers (3).
3. Remove the valve spring retainer (4) and remove

the valve spring (5).
g01015085
Table 2 Illustration 24
Typical example
Required Tools
Part Number Part Description Qty 1. Place the new valve springs (5) into position on
the cylinder head.
27610235 Adapter 1 2. Install the valve spring retainer (4).
3. Install the valve spring compressor (1) and the

NOTICE adapter (2) in position on the cylinder head in
Keep all parts clean from contaminants. order to compress the appropriate valve spring
(5). Compress the valve spring (5).
component life.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
Improper assembly of parts that are spring loaded 4. Install two valve keepers (3) in order to lock the
can cause bodily injury. valve springs in position.
To prevent possible injury, follow the established
assembly procedure and wear protective equip- NOTICE
ment. Do not turn the crankshaft while the valve springs are
removed.
NOTICE 5. Carefully release the pressure on the valve

Install suitable plugs to the inlet ports of the cylinder spring compressor (1). Remove the valve spring
head in order to prevent the entry of loose parts into compressor. Ensure that all of the valves are
the engine. secured in place by a valve spring and valve
keepers. Rotate the crankshaft through about
45 degrees in order to clear the piston from the
valve. Lightly strike the top of the valve with a soft
hammer in order to ensure that the valve keepers
(3) are properly installed.
Note: If you are replacing all of the valve springs,

on four cylinder engines only, the procedure can
be done on two cylinders at the same time. The
procedure can be done on cylinder 1 and cylinder 4,
or on cylinder 2 and cylinder 3.
SENR9973 19
End By:
a. Install the rocker shaft assembly. Refer to

Personal injury can result from being struck by
Disassembly and Assembly, “Rocker Shaft and
parts propelled by a released spring force.
Pushrod - Install”.
Make sure to wear all necessary protective equip-
i02187989 ment.
Inlet and Exhaust Valves - Follow the recommended procedure and use all
Remove and Install recommended tooling to release the spring force.
Removal Procedure
Table 3
Required Tools
27610235 Adapter 1
Start By:
g01015085
Illustration 25
a. Remove the cylinder head. Refer to Disassembly Typical example
and Assembly, “Cylinder Head - Remove”.
4. Install the 21825666 Valve Spring Compressor
NOTICE (1) and the 27610235 Adapter (2) in position
Keep all parts clean from contaminants. on the cylinder head in order to compress the
appropriate valve spring (5).
component life. NOTICE
Note: The removal procedure is identical for the or damage to the valve stem may occur.
engines. The illustrations show the four cylinder 5. Apply pressure to the valve spring compressor
engine. (1). Remove the valve keepers (3).
1. Clean the bottom face of the cylinder head. 6. Slowly release the pressure on the valve spring
Check the depth of the valves below the face of compressor (1).
the cylinder head before the valve springs are
removed. Refer to Specifications, “Cylinder Head
Valves” for the correct dimensions.
2. Place an identification mark on the heads of the

valves for installation purposes.
Note: The head of the inlet valve has a larger

diameter than the head of the exhaust valve.
3. Position the cylinder head on a suitable surface

with the valve springs facing upward.
Note: Ensure that the machined face of the cylinder

head is kept on a clean, soft surface in order to
prevent damage to the machined surface.
20 SENR9973
1. Clean all parts. Ensure that all ports, all coolant

passages and all lubrication passages are free
from debris. To inspect the cylinder head, refer to
Testing and Adjusting, “Cylinder Head Inspect”
for further information.
2. Inspect all of the valve seats for wear and for

damage. Refer to Specifications, “Cylinder Head
Valves” and refer to Testing and Adjusting, “Valve
Depth - Inspect ” for further information.
3. Inspect all of the valve guides for wear and for

damage. Refer to Specifications, “Cylinder Head
Valves” and refer to Testing and Adjusting , “Valve
Guide - Inspect” for further information.
g01113619
Illustration 26
Typical example
7. Remove the valve spring retainer (4).
8. Remove the valve spring (5).
9. Repeat steps 4 to 8 for the remaining valves.
10. Remove the valve spring compressor (1) and the

adapter (2).
11. Remove the valve stem seals (6).
12. Carefully turn over the cylinder head.

g01113619
Illustration 27
13. Remove the valves (7). Typical example
Installation Procedure 4. Lubricate the stems of all valves (7) with clean
engine oil. Install the valves (7) in the appropriate
Table 4 positions.
Required Tools
5. Carefully turn over the cylinder head and ensure
Part Number Part Description Qty that all of the valves remain in place.
6. Use a suitable tool to install the new valve stem
27610235 Adapter 1 seals (6) onto each of the valve guides.
Note: The outer face of the valve guides must be

NOTICE clean and dry before installing the valve stem seals
Keep all parts clean from contaminants. (6). The inlet valve stem and the exhaust valve stem
use seals that are different parts.
component life. 7. Inspect the valve springs (5) for wear and for the
correct installed length. Refer to Specifications,
Note: The installation procedure is identical for the “Cylinder Head Valves ” for further information.
engines. The illustrations show the four cylinder 8. Install the valve spring (5) onto the cylinder head.
engine.
SENR9973 21
9. Install the valve spring retainer (4). 14. Remove the valve spring compressor (1) and the
adapter (2) from the cylinder head.
15. Place the cylinder head on a suitable support.

Ensure that the heads of the valves are not
Personal injury can result from being struck by obstructed. Gently strike the top of the valves with
parts propelled by a released spring force. a soft hammer in order to ensure that the valve
keepers (3) are properly installed.
ment. 16. Turn over the cylinder head and check the depth
of the valves below the face of the cylinder head.
Follow the recommended procedure and use all Refer to Specifications, “Cylinder Head Valves” for
recommended tooling to release the spring force. more information.
End By:
a. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.
i02182148
Engine Oil Line - Remove and

Install
Illustration 28
g01015303 Removal Procedure
Typical example
NOTICE
10. Install the 21825666 Valve Spring Compressor

(1) and the 27610235 adapter (2) in position
on the cylinder head in order to compress the
appropriate valve spring (5).
NOTICE
11. Apply pressure to the valve spring compressor

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

when the valve spring compressor is released. En-
sure that the valve keepers are properly installed
on the valve stem. To help prevent personal injury,
keep away from the front of the valve keepers and g01117696
Illustration 29
valve springs during the installation of the valves.
Typical example
12. Carefully release the pressure on the valve spring 1. Loosen the nut (2) that attaches the oil line (1) to
compressor (1). the fuel injection pump.
13. Repeat steps 8 to 12 for all of the valves.
22 SENR9973
2. Remove the banjo bolt (3) and remove the Installation Procedure
washers (4) from the cylinder block. Discard the
washers (4).
g01117697
Illustration 30
Typical example
3. Remove the banjo bolt (3) and remove the

washers (4) from the cylinder head. Discard the Illustration 31
g01117696
washers (4). Typical example
4. Remove the oil line (1) from the engine. 1. Position the oil line (1) on the engine.
2. Position the banjo bolt (3) and the new washers

(4) on the oil line (1). Install the oil line to the
cylinder block.
g01117697
Illustration 32
Typical example
SENR9973 23
3. Position the banjo bolt (3) and the new washers

(4) to the oil line (1). Install the oil line to the
cylinder head.
4. Install the nut (2) that attaches the oil line (1) to
the fuel injection pump.
For the 402C-05, 403C-07, 403C-11 and 404C-15

engines, tighten the nut (2) to a torque of 6 N·m
(4.4 lb ft).
For the 403C-15, 404C-22 and 404C-22T engines,

tighten the nut (2) to a torque of 15 N·m (11 lb ft).
5. Tighten the banjo bolts (3) to 11.5 N·m (8.5 lb ft).
i02186236
Engine Oil Cooler - Remove

and Install
g01113679
Illustration 33
2. By using a suitable strap wrench, remove the

Removal Procedure oil filter element (5) from the oil cooler body (3).
Discard the oil filter element in a suitable manner.
NOTICE
Keep all parts clean from contaminants. 3. Remove the hose clamps (2) and the hoses (1)
from the coolant inlet and the coolant outlet on
Contaminants may cause rapid wear and shortened the oil cooler body (3). Note the positions of the
component life. coolant inlet and the coolant outlet for installation.
4. Remove the adapter (4) from the oil cooler body

NOTICE (3). Remove the oil cooler body (3) from the
Care must be taken to ensure that fluids are contained cylinder block (7).
ing, adjusting, and repair of the product. Be prepared 5. Remove the O-ring (6) from the oil cooler body
to collect the fluid with suitable containers before (3). Discard the O-ring.
ponent containing fluids. Installation Procedure
mandates. NOTICE
1. Drain the coolant from the cooling system into Contaminants may cause rapid wear and shortened
a suitable container. Drain the engine oil into a component life.
suitable container. Refer to the Operation and
Maintenance Manual for the procedure on draining
the coolant and the engine oil. 1. Clean the mating surfaces of the oil cooler base
on the cylinder block (7) and clean the oil cooler
body (3).
2. Install a new O-ring (6) to the oil cooler body (3).

Install the oil cooler body (3) to the cylinder block
(7).
3. Install the adapter (4) through the oil cooler body

(3) to the cylinder block (7). Tighten the adapter
(4) to a torque of 34 N·m (25 lb ft).
24 SENR9973
4. Install the appropriate hoses (1) to the coolant 1. Remove the engine oil relief valve (2) from the
inlet and the coolant outlet on the oil cooler body cylinder block.
(3). Tighten the hose clamps (2).
2. Remove the O-ring (1) from the engine oil relief
5. Lubricate the O-ring of the oil filter element (5) valve. Discard the O-ring.
with clean engine oil. Install the new oil filter
element to the oil cooler body (4). Tighten the oil
filter element by hand. Do not use a strap wrench
to tighten the oil filter element.
NOTICE
6. Fill the cooling system with coolant. Fill the Keep all parts clean from contaminants.
lubrication system with engine oil. Refer to the
Operation and Maintenance Manual, “Refill Contaminants may cause rapid wear and shortened
Capacities” for the cooling system capacity and component life.
for the lubrication system capacity of the engine.
i02182334
Engine Oil Relief Valve -

Remove and Install
Removal Procedure
NOTICE
g00820218
Illustration 35
component life. 1. Install a new O-ring (1) on the engine oil relief
valve (2).
NOTICE
Care must be taken to ensure that fluids are contained 2. Lubricate the engine oil relief valve (2) with clean
during performance of inspection, maintenance, test- engine oil.
to collect the fluid with suitable containers before 3. Install the engine oil relief valve (2) in the cylinder
opening any compartment or disassembling any com- block. Tighten the engine oil relief valve to a
ponent containing fluids. torque of 64 N·m (47 lb ft).
Dispose of all fluids according to local regulations and i02182152

mandates.
Engine Oil Pump - Remove
Removal Procedure
Start By:
a. Remove the front housing. Refer to Disassembly

and Assembly, “Housing (Front) - Remove”.
NOTICE
Illustration 34
g00820218 Contaminants may cause rapid wear and shortened
component life.
SENR9973 25
3. Remove the idler gear (3) from the idler hub (1).
NOTICE
If the front housing is not installed, do not turn the 4. Remove the thrust washer (2) from the idler hub
crankshaft. Damage to the engine may occur. (1).
5. Inspect all the components for wear or damage.

NOTICE Any components that are worn or damaged should
Care must be taken to ensure that fluids are contained be replaced with new parts.
ing, adjusting, and repair of the product. Be prepared Note: Refer to Specifications, “Engine Oil Pump” for
to collect the fluid with suitable containers before more information.
ponent containing fluids. 6. If the engine oil pump has excessive buildup of
sludge, inspect the oil strainer. The oil strainer can
Dispose of all fluids according to local regulations and be removed by using the following procedure:
mandates.
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
Engine Oil Pump Remove and Install”.
g00825411 g00825406
b. Remove the setscrews (12) and the oil strainer

(13) from the cylinder block. Inspect the
oil strainer for damage. If the oil strainer is
damaged, use a new part for replacement.
c. Remove the oil tube (11) from the cylinder
block.
ment.
d. Remove the O-ring (10) from the oil tube.
Discard the used O-ring.
1. Remove the C-clip (9) that retains the idler gear

(3) on the idler hub (1).
2. Remove the following items from the idler hub (1):
• Collar (8)
• Spring (7)
• Shim (6)
• Oil pump cover (5)
• Inner rotor (4)
26 SENR9973
Idler Hub
NOTICE

component life.
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
Idler Hub
Note: Always install a new idler hub. Do not install
a used hub. A used hub may have been damaged
during removal from the cylinder block.
g00831103
Illustration 38
Typical example
1. Remove the crankshaft. Refer to Disassembly and

Assembly, “Crankshaft - Remove”.
2. Use a hammer and use a suitable drift to remove

idler hub (1) from the cylinder block (2). Align the
drift to the rear face of the hub and drive the hub
from the inside of the cylinder block outward.
g01113447
Illustration 39
i02182347 Typical example
Engine Oil Pump - Install 1. Install the alignment pin (3) to the cylinder block
(4).
2. Install the idler hub (2) into the installation tool (1).
Installation Procedure Position the idler hub (2) and the installation tool
(1) onto the alignment pin (3) so that the hub is
Table 5 squarely engaged into the cylinder block (4).
Required Tools
3. Use a suitable hammer to strike the installation
Part Number Part Description Qty tool (1) until the hub (2) is fully engaged into the
cylinder block (4).
Installation Tool and Alignment
21825624 Pin for engines 402C-05, 1
403C-07
403C-15
404C-22, 404C-22T
SENR9973 27
Engine Oil Pump


ment.

4. Install the following items to the idler hub (1):
• Oil pump cover (5)

g00825411
Illustration 40 • Shim (6)
Typical example
(1) Idler shaft • Spring (7)
(2) Thrust washer
(3) Idler gear • Collar (8)
(4) Inner rotor
(5) Oil pump cover
(6) Shim
5. Install the C-clip (9) on the idler shaft (1).
(7) Spring
(8) Collar 6. Check the end play of the oil pump. Refer to
(9) C-clip Specifications, “Engine Oil Pump”.
1. Apply a suitable multipurpose grease to the faces 7. Check the backlash of the gear group. Refer to
of the inner rotor (4) and to the vanes of idler gear Specifications, “Gear Group Inspect”.
(3).
8. If the oil strainer was removed, use the following
procedure for installation:
g01114781
Illustration 42
Typical example
a. Install a new O-ring (17) on the oil tube (16).

g01114780
Illustration 41
Typical example
b. Install the oil tube (16) in the cylinder block.
2. Align the timing marks (13) and (12) on the idler c. Install the oil strainer (14) on the cylinder block
gear (3) to the respective timing marks on the and tighten the setscrews (15) to a torque of
camshaft gear (10) and the crankshaft gear (11). 11 N·m (8 lb ft).
Install the idler gear (3) to the idler shaft (1).
End By:
3. Install the inner rotor (4) to the idler gear (3).
a. Install the front housing. Refer to Disassembly and
Assembly, “Housing (Front) - Install”.
28 SENR9973
b. Install the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and
Install”.
i02242485
Water Pump - Remove
Removal Procedure (403C-11,

403C-15, 404C-15, 404C-22 and
404C-22T Engines) g01124100
Illustration 43
Start By: Typical example
a. Remove the fan. Refer to Disassembly and 3. Remove the fasteners (2) and the alternator
Assembly, “Fan - Remove and Install”. bracket (1) from the water pump (3).
b. Remove the alternator. Refer to Disassembly and

Assembly, “Alternator - Remove and Install”.
NOTICE

component life.
NOTICE

mandates.
g01124257
Illustration 44
1. Drain the coolant from the cooling system into a Typical example
suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, “Refill 4. Loosen the clamps (2) and remove the bypass
Capacities” for the approximate capacity of the hose (3) from the water pump (6).
cooling system.
5. Remove the setscrews, the washers (4) and the
2. Loosen the clamps and remove the hose from the nut (5).
water pump inlet (not shown).
6. If necessary, gently tap the water pump (6) with a
soft faced hammer in order to loosen the water
pump (6).
7. Remove the water pump (6). Remove the joint (1)

from the cylinder block. Discard the joint (1).
SENR9973 29
Removal Procedure (402C-05 and

403C-07 Engines)
Start By:
a. Remove the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.
b. Remove the alternator. Refer to Disassembly and

Assembly, “Alternator - Remove and Install”.
NOTICE

component life.
NOTICE
during performance of inspection, maintenance, test- g01124046
Illustration 46
to collect the fluid with suitable containers before Typical example
ponent containing fluids. 4. Loosen the clamps (3) and remove the bypass
hose (4) from the water pump (7).
mandates. 5. Remove the setscrews, the washers (5) and the
nut (6).
1. Drain the coolant from the cooling system into a 6. If necessary, gently tap the water pump (7) with a
suitable container for storage or disposal. Refer soft faced hammer in order to loosen the water
to Operation and Maintenance Manual, “Refill pump (7).
Capacities” for the approximate capacity of the
cooling system. 7. Remove the water pump (7). Remove the joint (8),
the spacer (1), and the joint (2) from the cylinder
2. Loosen the clamps and remove the hose from the head. Discard the joint (8) and the joint (2).
water pump inlet (not shown).
i02182929
Water Pump - Install
Installation Procedure (403C-11,

403C-15, 404C-15, 404C-22 and
404C-22T Engines)
NOTICE
g01124100
Illustration 45
typical example
component life.
3. Remove the fasteners (2) and the alternator
bracket (1) from the water pump (3). 1. Remove all debris and gasket material from
the mating surfaces of the water pump and the
cylinder block.
30 SENR9973
End By:
a. Fill the cooling system with coolant to the correct

level. Refer to Operation and Maintenance
Manual, “Refill Capacities”.
b. Install the pulley, the adapter and the fan. Refer

to Disassembly and Assembly, “Fan - Remove
and Install”.
c. Install the V-Belts. Refer to Disassembly and

Assembly, “V-Belts - Remove and Install”.
Installation Procedure (402C-05

and 403C-07 Engines)
NOTICE

g01124257
Illustration 47 component life.
Typical example
1. Remove all debris and gasket material from

2. Install a new gasket (1) in position on the engine. the mating surfaces of the water pump and the
cylinder block.
3. Place the water pump (6) in position on the engine
and install the setscrews, the washers (4) and the
nut (5). Tighten setscrews, the washers (4) and
the nut (5) to a torque of 10 N·m (7.4 lb ft).
g01124637
Illustration 48
Typical example
g01124046
4. Place the alternator bracket (1) into position on Illustration 49
water pump (6). Install the fasteners (2) on the Typical example
water pump (6) and hand tighten the fasteners (2).
2. Install new gaskets (8) and (2) and the spacer (1)
5. Install the lower hose and install the hose clamp in position on the engine.
(not shown). Hand tighten the hose clamp. Install
the hose (3) on the water pump (6) and tighten the 3. Place the water pump (7) in position on the engine
hose clamps (2) to a torque of 2.5 N·m (22.1 lb in). and install the setscrews, the washers (5) and the
nut (6). Tighten setscrews, the washers (5) and
the nut (6) to a torque of 10 N·m (7.4 lb ft).
SENR9973 31
NOTICE

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

g01124662 to the OEM for the approximate capacity of the
Illustration 50
Typical example cooling system. Refer to the Operation and
Maintenance Manual, “Cooling System Coolant
4. Place the alternator bracket (1) into position on (DEAC) - Change” or Operation and Maintenance
water pump (7). Install the fasteners (2) on the Manual, “Cooling System Extended Life Coolant
water pump (7) and hand tighten the fasteners (2). - Change”.
5. Install the lower hose and install the hose clamp

(not shown). Hand tighten the hose clamp. Install
the hose (4) on the water pump (7) and tighten the
hose clamps (3) to a torque of 2.5 N·m (22.1 lb in).
End By:
a. Fill the cooling system with coolant to the correct

Manual, “Refill Capacities”.
b. Install the pulley, the adapter and the fan. Refer

to Disassembly and Assembly, “Fan - Remove
and Install”. g01124076
Illustration 51
c. Install the V-Belts. Refer to Disassembly and Typical example
2. Remove the setscrews (4) and the nuts (3).
i02182980 3. Remove the water temperature regulator housing
Water Temperature Regulator (2) from the cylinder head.
Housing - Remove and Install 4. Remove the gasket (1) from the cylinder head.
Discard the gasket.
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
component life.
1. Clean the mating surfaces of the cylinder
head. Clean the mating surfaces of the water
temperature regulator housing.
32 SENR9973
NOTICE

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

Illustration 52
g01124076 to Operation and Maintenance Manual, “Refill
Typical example
cooling system.
2. Install a new gasket (1) on the cylinder head.
3. Install the water temperature regulator housing

(2) to the cylinder head.
4. Install the setscrews (4) and the nuts (3) that

fasten the water temperature regulator housing
to the cylinder head. Tighten the fasteners to a
torque of 10 N·m (7.4 lb ft).
5. Fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance
Manual, “Refill Capacities” for more information.
g01112497
i02182987 Illustration 53
Water Temperature Regulator - Typical example
Remove and Install

Personal injury can result from parts and/or cov-
ers under spring pressure.
Removal Procedure (402C-05 and
403C-07 engines) Spring force will be released when covers are re-
moved.
NOTICE Be prepared to hold spring loaded covers as the

Keep all parts clean from contaminants. bolts are loosened.

component life. 2. Remove the setscrews (6) and the nuts (5).
3. Remove the outlet connection (4) for the water

temperature regulator.
4. Remove the joint (3).
5. Remove the water temperature regulator (2) and

the spring (1) from the cylinder head.
SENR9973 33
6. Inspect the water temperature regulator (2) 3. Remove the outlet connection (2) for the water
for wear or damage. If the water temperature temperature regulator.
regulator is worn or damaged, use a new part
for replacement. Refer to Testing and Adjusting, Note: Identify the orientation of the outlet connection
“Water Temperature Regulator - Test” for more for installation.
information on testing the water temperature
regulator. 4. Remove the joint (3).
5. Remove the water temperature regulator (4) from

Removal Procedure (403C-11, the water temperature regulator housing (5).
403C-15, 404C-15, 404C-22 and
404C-22T engines) 6. Inspect the water temperature regulator (4)
for wear or damage. If the water temperature
regulator is worn or damaged, use a new part
NOTICE for replacement. Refer to Testing and Adjusting,
Keep all parts clean from contaminants. “Water Temperature Regulator - Test” for more
information on testing the water temperature
Contaminants may cause rapid wear and shortened regulator.
component life.
NOTICE and 403C-07 engines)
ing, adjusting, and repair of the product. Be prepared NOTICE
to collect the fluid with suitable containers before Keep all parts clean from contaminants.
ponent containing fluids. Contaminants may cause rapid wear and shortened
component life.
mandates. 1. Remove all debris and gasket material from the
mating surfaces of both the outlet connection
1. Drain the coolant from the cooling system into a (4) for the water temperature regulator and the
suitable container for storage or disposal. Refer cylinder head.
to Operation and Maintenance Manual, “Refill
cooling system.

ment.

g01125880
Illustration 54
Typical example
g01112497
Illustration 55
2. Remove the setscrews (1).
34 SENR9973
2. Install the spring (1) and the water temperature 2. Install the water temperature regulator (4) to the
regulator (2) to the cylinder head. water temperature regulator housing (5). Refer
to specifications, “Water Regulator Housing
Note: Install the water temperature regulator with the for 403C-11, 403C-15, 404C-15, 404C-22and
jiggle pin in the vertically upward position. 404C-22T Engines” for the correct orientation of
the water temperature regulator.
3. Install a new joint (3) to the cylinder head.
3. Install a new joint (3) to the cylinder head.
4. Install the outlet connection (4) to the cylinder
head. 4. Install the outlet connection (2) to the water
temperature regulator housing (5).
5. Install the nut (5) and the setscrews (6) to the
outlet connection (4). Note: Ensure the correct orientation of the outlet
connection.
6. Tighten the fasteners to a torque of 6 N·m
(53 lb in). 5. Install the setscrews (1) to the outlet connection
(2).
level. Refer to Operation and Maintenance 6. Tighten the setscrews to a torque of 14 N·m
Manual, “Refill Capacities” for more information. (10 lb ft).

Installation Procedure (403C-11, level. Refer to Operation and Maintenance
403C-15, 404C-15, 404C-22 and Manual, “Refill Capacities” for more information.
404C-22T engines)
i02183594
NOTICE
Flywheel - Remove
component life.
Removal Procedure
1. Remove all debris and all gasket material from the Start By:
mating surfaces of both the outlet connection (2)
and the water temperature regulator housing (5). a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
NOTICE

component life.
Note: The two cylinder, the three cylinder and the

four cylinder engines have different flywheels. The
removal procedure is similar for all models.
g01125880
Illustration 56
SENR9973 35
g01123637
Illustration 57
Typical example
1. Install a suitable lifting device (1) to the flywheel

(2).
2. Remove two setscrews (3) opposite each other Illustration 58

g01123614
from the flywheel.
Typical example
3. Install two suitable guide studs in the place of the

setscrews that were removed. 7. To remove the flywheel ring gear (5) from the
flywheel (2), place the flywheel on a suitable
4. Remove the remaining setscrews (3) that fasten support. Use a suitable hammer (not shown) and
the flywheel to the crankshaft. a punch (4) in order to remove the ring gear from
the flywheel.
5. Remove the flywheel (2) from the rear of the
crankshaft. i02183590
Note: On some three cylinder engines, a roll pin is Flywheel - Install

located between the crankshaft and the flywheel.
6. Inspect the flywheel ring gear (5) and the flywheel

(2) for wear or damage. If the flywheel ring gear or Installation Procedure
the flywheel is worn or damaged, use new parts
for replacement.
NOTICE

component life.
Always wear protective gloves when handling

parts that have been heated.
36 SENR9973

(1).
4. Install two suitable guide studs opposite each

other in the end of the crankshaft.
5. Position the flywheel (1) onto the two guide studs.
On three cylinder engines that have a roll pin,

ensure that the roll pin is installed to the crankshaft
and that the roll pin is free from damage. Align
the hole in the flywheel with the roll pin in the
crankshaft.
g01124041
6. Install the setscrews (5) that fasten the flywheel
Illustration 59 to the crankshaft.
Typical example
7. Remove the two guide studs and install the two
1. Thoroughly clean the flywheel housing. Inspect remaining setscrews (5) in the flywheel.
the crankshaft rear seal for leaks. If there are
any oil leaks refer to Disassembly and Assembly, 8. Use a suitable tool to prevent the flywheel (1) from
“Crankshaft Rear Seal - Remove”. rotating. Tighten the setscrews (5) to a torque of
73.5 N·m (54.2 lb ft).
2. If necessary, perform the following procedure to
install the ring gear (2) to the flywheel (1). 9. Remove the lifting device (4) from the flywheel.
a. Identify the orientation of the new ring gear in Note: Refer to Specifications, “Flywheel” for
order to install the ring gear correctly onto the information on flywheel runout.
flywheel.
End By:
Note: The chamfered side of the gear teeth (3) must
face toward the starting motor when the flywheel is a. Install the electric starting motor. Refer to
installed. This will ensure the correct engagement of Disassembly and Assembly, “Electric Starting
the starting motor. Motor - Remove and Install”.
b. Heat the flywheel ring gear (2) in an oven to a

i02183600
maximum temperature of 150°C (302°F) prior
to installation. Crankshaft Rear Seal - Remove
Note: Do not use a torch to heat the ring gear.
c. Ensure that the orientation of the ring gear (2)

is correct and quickly install the ring gear onto Removal Procedure
the flywheel (1).
Start By:
a. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
NOTICE

component life.
g01124042
Illustration 60
Typical example
SENR9973 37
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Keep all parts clean from contaminants.
ing, adjusting, and repair of the product. Be prepared Contaminants may cause rapid wear and shortened
to collect the fluid with suitable containers before component life.

mandates.
Note: The two cylinder, the three cylinder and the

four cylinder engines have different configurations for
the flywheel housing and the backplate. The removal
process is similar for all models.
g00847841
Illustration 61
Typical example
1. Remove the setscrews (3) and the backplate (2)

from the rear of the cylinder block.
2. Remove the crankshaft rear seal (1) from the

cylinder block. Discard the used crankshaft oil
seal.
i02183601
Crankshaft Rear Seal - Install
Note: Inspect the crankshaft rear seal and replace
the assembly if there is the slightest sign of damage
to the seal.
Note: The following procedure assumes that the

crankshaft rear seal is a replacement assembly.
38 SENR9973
g01113706
Illustration 62
Typical example
1. Clean the rear face of the cylinder block (1) and 6. Ensure that the plastic sleeve is engaged onto
the backplate (6). Inspect the dowels (3) for the crankshaft flange (4). Push the crankshaft
damage. If the dowels are damaged, use new rear seal (5) evenly and push the crankshaft rear
parts for replacement. seal smoothly onto the crankshaft flange until
the crankshaft rear seal is against the cylinder
2. Ensure that the crankshaft flange (4) is clean, dry block. During this process, the plastic sleeve will
and free from rough metal edges. be forced out of the crankshaft rear seal. Discard
the plastic sleeve.
3. Remove the packaging from the new crankshaft
rear seal (5). Ensure that the plastic sleeve (not 7. Apply a continuous bead of 21826038
shown) is squarely installed within the crankshaft POWERPART Silicone Adhesive to the rear face
rear seal. The plastic sleeve is included in order of the cylinder block around the mating surface of
to protect the lip of the seal as the lip is pushed the crankshaft rear seal and around the rear core
over the crankshaft flange. plug for the camshaft (2).
4. Apply clean engine lubricating oil to the crankshaft 8. Align the backplate (6) to the dowels (3) and install
flange (4) around the running surface of crankshaft the backplate to the cylinder block (1).
rear seal.
9. Install the setscrews (7) that fasten backplate (6)
5. Place the crankshaft rear seal (5) over the to the cylinder block (1).
crankshaft flange (4) and engage the plastic
sleeve onto the crankshaft flange. For the 402C-05 and 403C-07 engines, tighten
the setscrews to a torque of 15 N·m (11 lb ft).
SENR9973 39
For the 403C-11 and 404C-15 engines, tighten the 3. Remove the setscrews (3) that fasten the flywheel
setscrews to a torque of 50 N·m (37 lb ft). housing (8) to the cylinder block.
For the 403C-15, 404C-22 and 404C-22T engines, 4. Remove the setscrews (5) on each side of
tighten the setscrews to a torque of 25 N·m the cylinder block. These setscrews fasten the
(19 lb ft). flywheel housing (8) to the cylinder block.
End By: 5. Remove the setscrews (1) that fasten the

backplate (2) to the flywheel housing (8).
a. Install the flywheel housing. Refer to Disassembly
and Assembly Manual, “Flywheel Housing - 6. Remove the nuts (7) and the bolts (not shown)
Remove and Install”. that fasten the backplate (2) to the flywheel
housing (8).
b. Install the flywheel. Refer to Disassembly and
Assembly Manual, “Flywheel - Install”.
i02183603
Flywheel Housing - Remove

and Install
Removal Procedure (Engines with

Flywheel Housing and Backplate)
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
NOTICE
Keep all parts clean from contaminants. Illustration 64
g01113237
Typical example
component life. 7. Use the lifting device (9) to remove the flywheel
housing (8) from the backplate.
1. Support the engine with a suitable lifting device or
support the engine on blocks that are positioned Removal Procedure (Engines with
on a flat level surface.
Flywheel Housing)
housing and support the weight of the housing (8). Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
NOTICE

component life.
cylinder engines have different flywheel housings.
The removal procedure is similar for all models.
g00827061
Illustration 63
Typical example
40 SENR9973
1. Support the engine with a suitable lifting device or Installation Procedure (Engines
support the engine on blocks that are positioned
on a flat level surface.
with Flywheel Housing and
Backplate)
housing and support the weight of the housing (2). NOTICE

component life.
g01123577
Illustration 65
Typical example
3. Remove the setscrews (1) that fasten the flywheel

housing (2) to the cylinder block. g00827061
Illustration 67
Typical example
1. Clean the rear face of the backplate (2) and the

faces of the flywheel housing (8). Inspect the
crankshaft rear seal (not shown) for leaks. Inspect
the dowels (6) for damage. If the crankshaft
rear seal or the dowels are damaged, use new
parts for replacement. Refer to Disassembly and
Assembly, “Crankshaft Rear Seal - Remove” and
Disassembly and Assembly, “Crankshaft Rear
Seal - Install”.
g01123555
Illustration 66
Typical example
4. Use the lifting device (3) to remove the flywheel

housing (2) from the engine.
SENR9973 41
Installation Procedure (Engines

with Flywheel Housing)
NOTICE

component life.
g01113237
Illustration 68
Typical example
g01123556
2. Use the lifting device (9) to align the flywheel Illustration 69
housing (8) to the dowels (6). Install the flywheel Typical example
housing to the backplate.
1. Clean the mating face of the flywheel housing
3. Install the nuts (7) and the bolts (not shown) that (2). Inspect the crankshaft rear seal (4) for
fasten the backplate (2) to the flywheel housing leaks. Inspect the dowels (5) for damage. If
(8). the crankshaft rear seal or the dowels are
damaged, use new parts for replacement. Refer
4. Install the setscrews (1) that fasten the backplate to Disassembly and Assembly, “Crankshaft Rear
(2) to the flywheel housing (8). Seal - Remove” and Disassembly and Assembly,
“Crankshaft Rear Seal - Install”.
5. Install the setscrews (5) on each side of the
cylinder block. These setscrews fasten the
flywheel housing (8) to the cylinder block.
6. Remove the lifting device (9) from the flywheel

housing.

housing (8) to the cylinder block.
8. For 403C-15, 404C-22 and 404C-22T engines,

tighten the fasteners to a torque of 25 N·m
(19 lb ft).
End By:
a. Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.
g01123555
Illustration 70
Typical example
2. Use the lifting device (3) to align the flywheel

housing (2) to the dowels (5). Install the flywheel
housing to the engine.
42 SENR9973

housing to the cylinder block.
For 402C-05 and 403C-07 engines, tighten the


For 403C-15 engines, tighten the setscrews to a

4. Remove the lifting device (3) from the flywheel

housing.
g01122953
End By: Illustration 72
a. Install the flywheel. Refer to Disassembly and 2. Install the 21825619 Puller (6) to the crankshaft
Assembly, “Flywheel - Install”. pulley. Use the puller (6) in order to remove the
crankshaft pulley (2) from crankshaft (4).
i02183604 3. Remove the woodruff key (1) from the crankshaft

(4).
Crankshaft Pulley - Remove
and Install Installation Procedure
Removal Procedure
Table 6
Required Tools
Part Number Description Qty
21825619 Puller 1
1. Remove the fan drive belt. Refer to Disassembly

and Assembly, “V Belts Remove and Install” for
more information.
g00827213
Illustration 73
Note: Inspect the following components for damage:

the taper of the crankshaft, the woodruff key, and
the bore of the crankshaft pulley. Replace any
components that are damaged. Ensure that the taper
of the crankshaft and the bore of the crankshaft
pulley are clean and dry before assembly.
1. Install the woodruff key (1) to the crankshaft (4).
2. Install the crankshaft pulley (2) to the crankshaft

(4).
3. Install the washer (3) to the crankshaft (4).

g00827213
Illustration 71
4. Lubricate the nut (5) with clean engine oil and
1. Remove the nut (5) and the washer (3) from install the nut.
crankshaft pulley (2).
nut (5) to a torque of 93 N·m (69 lb ft).
SENR9973 43
For 403C-11 and 404C-15 engines, tighten the nut i02187983

(5) to a torque of 123 N·m (91 lb ft).
Crankshaft Front Seal - Install
tighten the nut (5) to a torque of 304 N·m (224 lb ft).
5. Install the V-belt to the engine. Refer to Installation Procedure

Disassembly and Assembly, “V Belts Remove and
Install” for more information. NOTICE
i02200446
Crankshaft Front Seal - component life.
Remove
Removal Procedure
NOTICE

component life.
NOTICE
Care must be taken to ensure that fluids are contained Illustration 74
g01113392
ing, adjusting and repair of the product. Be prepared to 1. Clean the bore of the housing (1) for the crankshaft
collect the fluid with suitable containers before open- front seal (2) and inspect the bore of the housing
ing any compartment or disassembling any compo- for any damage.
nent containing fluids.
2. Lubricate the crankshaft front seal (2) with clean
Dispose of all fluids according to local regulations and engine oil.
mandates.
3. Position the crankshaft front seal (2) in the bore of
Remove the Front Oil Seal that is installed the housing (1) for the crankshaft front seal.
in the Engine
NOTICE
1. If the front cover is still attached to the engine, Ensure that the lip of the crankshaft front seal that is
use a suitable lever in order to remove the oil seal spring loaded is facing toward the inside of the front
from the front cover. housing and that it is square with the bore of the hous-
ing for the crankshaft front seal.
Remove the Front Oil Seal from a
Disassembled Front Cover 4. Use a suitable tool (3) to install the new crankshaft
front seal (2).
1. If the front cover has been removed from the
engine, use a suitable hydraulic press in order to Note: Apply clean engine oil on the area of the
remove the oil seal from the front cover. Ensure crankshaft pulley that will be in contact with the
that the front cover is supported correctly in order crankshaft front seal (2).
to prevent damage to the cover while the oil seal
is being removed. End By:
a. Install the crankshaft pulley and the V-belt. Refer

to Disassembly and Assembly, “Crankshaft Pulley
44 SENR9973
i02186336
Housing (Front) - Remove
Removal Procedure
Start By:
a. Remove the fuel injection pump. Refer to

Disassembly and Assembly, “Fuel Injection Pump
- Remove”.
b. Remove the crankshaft pulley. Refer to

Disassembly and Assembly, “Crankshaft Pulley
NOTICE

component life.
NOTICE
during performance of inspection, maintenance, test- g01129574
Illustration 75
to collect the fluid with suitable containers before Typical example
ponent containing fluids. 1. Remove the setscrews and the nuts (5) from the
front housing (4).
mandates. 2. Turn the mechanical stop lever (3) to the full
clockwise position so that the spring is held under
tension.
3. Remove the front housing (4) from the front of

cylinder block (6).
Note: Identify the position of the locating pin (2) and

the locating hole (1) for installation.
4. Remove the joint (not shown) from the cylinder

block (6) or from the front housing (4). Discard
the joint.
5. Inspect the front housing assembly (4) for wear

or damage. If the front housing assembly is
damaged, use new parts for replacement.
SENR9973 45
i02186302 Removal of the Throttle Control

Housing (Front) - Disassemble
Disassembly Procedure
Start By:
a. Remove the engine front housing. Refer to

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

component life.
NOTICE
g01114167
Illustration 76
mandates. Typical example
1. Remove the spring (5) from the lever (8) for the
throttle control.
2. Loosen the nut (1) and the bolt (4) that secures
the arm (3) to the lever (8) for the throttle control.
Note: Identify the position of the arm in relation to the

lever for installation. Do not remove the nut (1) and
the washers (2) from the bolt (4).
3. Remove the arm (3) from the lever (8).
4. Remove the C-clip (6) from the lever (8).
5. Remove the lever (8) from the front housing (9).
6. Remove the O-ring (7) from lever (8). Discard the

O-ring.
7. Check the components for wear or damage.

Replace any components that are worn or
damaged.
Removal of the linkage for the Fuel

Injection Pump
Note: When the linkage for the fuel injection pump is
removed or the engine front cover is replaced, the
setting for the maximum fuel may be affected.
46 SENR9973
Removal of the Stop Control
g01114517
Illustration 78
Typical example
1. Remove the nut (16) and remove the washer (17)

that secures the lever (18) to the arm (24) for the
Illustration 77
g01114159 stop control.
Typical example
2. Remove the lever (18) from the arm (24) for the
1. Remove the spring (10) from the lever assembly stop control.
(11).
Note: Identify the position of the lever (18) on the
2. Remove the C-clip (14) from the shaft (12). shaft (24) for installation.
3. Remove the shaft (12) and remove the lever 3. Remove the nut (19) from the arm (24) for the
assembly (11) from the engine front housing (9). stop control. Remove the washer (20) and remove
the spring (21) from the arm (24).
4. Remove the O-ring (13) from the shaft (12).
Discard the O-ring. 4. Remove the arm (24) for the stop control from the
front housing.
5. Remove the angleich unit (15) from the lever
assembly (11). 5. Remove the C-clip (23) and the O-ring (22) from
the arm (24). Discard the O-ring.
Note: The angleich unit is not installed to the
402C-05, 403C-07, 403C-11 and 404C-15 engines,
or engines that run at a constant speed.
6. Check the components for wear or damage.

Replace any components that are worn or
damaged.
SENR9973 47
Removal of the PTO Cover Installation of the Throttle Control
g01114513
Illustration 79
Typical example
1. Remove the nuts (25) and the bolts (31) from the
PTO cover.
2. Remove the plates (26) and (30). Illustration 80

g01114382
Typical example
Note: The plate (30) is not installed on 402C-05 or
403C-07 engines.
1. Install the O-ring (6) to the shaft of the lever (7).
3. Remove the joint (27) and discard the joint.
2. Lubricate the O-ring (6) and the shaft of the lever
4. Remove the O-ring (29). Discard the O-ring. (7) with clean engine oil. Install the lever (7) into
the front housing (8).
Note: The O-ring (29) is not installed on 402C-05
or 403C-07 engines. 3. Install the C-clip (5) onto the shaft of the lever (7).
5. Check the condition of all parts. Replace any parts 4. Install the arm for the throttle control (3) onto the
that are damaged or worn. lever (7). Tighten the nut (1) and bolt (4) to a
i02186295 Installation of the linkage for the Fuel

Housing (Front) - Assemble Injection Pump
1. If necessary, perform the following procedure to
install the angleich unit (15) to the lever assembly
(11).
Assembly Procedure
Note: If the engine front housing is replaced, ensure
that a new emissions label is installed.
48 SENR9973
g01114377
Illustration 81
a. Apply 21820117 POWERPART Threadlock to

the first two threads of the angleich unit (18).
b. Install the angleich unit (18) to the lever

assembly (11). Tighten the angleich unit to a
torque of 5 N·m (44 lb in).
Note: Ensure that no 21820117 POWERPART

Threadlock is allowed to contaminate the plunger
assembly of the angleich unit. Contamination of
the plunger assembly will render the angleich unit
inoperative.
g01114562
Illustration 82
Typical example
2. Install the spring (10) to the lever assembly (11).
3. Install the O-ring (13) to the shaft (12). Lubricate

the shaft with clean oil.
4. Position the lever assembly (11) in the front

housing (8). Install the shaft (12) to outside of the
front housing (8).
Note: Ensure that the groove for the C-clip (16) in

the shaft (12) is positioned between the boss (15) on
the front housing and the cast retainer (17) on the
front housing (8).
5. Install the C-clip (14) to the shaft (12).

SENR9973 49
3. Place the spring (24) and the washer (23) onto the
arm (27). Install the nut (22) onto the arm (27).
4. Install the lever (21) onto the arm (27).
5. Install the washer (20) and the nut (19) onto the
arm (27). Tighten the nuts (19) and (22) to a
Installation of the PTO Cover
g01114380
Illustration 83
Typical example
6. Attach the spring (10) to the notch on the inside

of the front housing (8).
7. Install the spring (9) to the lever assembly (11).
8. Attach the spring (9) to the lever (7).

g01114607
Installation of the Stop Control Illustration 85
Typical example
Note: The O-ring (32) and the plate (33) are not
installed on the 402C-05 and 403C-07 engines.
1. For 403C-11, 403C-15, 404C-15, 404C-22 and

404C-22T engines, install the O-ring (32) to the
groove in the front housing (31).
2. Install a new joint (30) to the rear of the front

housing.
3. For 403C-11, 403C-15, 404C-15, 404C-22 and

404C-22T engines, install the plates (29) and (33).
For 402C-05 and 403C-07 engines, install the

plate (29).
4. Install the nuts (28) and the bolts (34) for the PTO
cover. Tighten the nuts to a torque of 13 N·m
(10 lb ft).
g01114606
Illustration 84
End By:
Typical example
a. Install the front housing to the engine. Refer to
1. Install the C-clip (26) and install the O-ring (25) to Disassembly and Assembly, “Housing (Front)
the arm (27). Install” for more information.
2. Lubricate the O-ring (25) and the shaft of the arm
(27) with clean oil. Install the arm assembly (27) to
the front housing.
50 SENR9973
b. Check the maximum engine speed at no load.

Refer to Testing and Adjusting, “Engine Speed -
Check” for more information.
i02186325
Housing (Front) - Install
Table 7
Required Tools
21825620 Seal Guide 1
402C-05, 403C-07, 403C-11
and 404C-15 engines
21825621 Seal Guide 1
403C-15, 404C-22 and
404C-22T engines
NOTICE
g01113288
Contaminants may cause rapid wear and shortened Illustration 86
component life.
3. Align the locating pin (2) with the locating hole on
the oil pump cover (1). Ensure that the oil pump
1. Clean the front housing assembly (4) thoroughly. cover is concentric to the idler gear assembly.
2. For 402C-05, 403C-07, 403C-15 and 404C-11 4. Install a new joint to the front of the cylinder block
engines, install the 21825620 Seal Guide (6) to (7).
the crankshaft.
5. Turn the mechanical stop lever (3) to the full
For 403C-15, 404C-22 and 404C-22T engines, clockwise position so that the spring is held under
install the 21825621 Seal Guide (6) to the tension. Observe the position of the linkage for
crankshaft. the fuel injection pump (not shown) in the front
housing.
6. Position the front housing (4) on the front of

cylinder block (7). Guide the linkage for the fuel
injection pump into position so that the link is free
to move inside the aperture on the cylinder block
for the fuel injection pump.
7. Align the front housing (4) with the dowels in the

front of the cylinder block (7). Press the front
housing into position. Release the stop lever (3).
8. Install the fasteners (5) finger tight.
9. Tighten the fasteners (5) to a torque of 10 N·m

(7 lb ft).
10. Remove seal guide (6) from the crankshaft.

SENR9973 51
Note: If the front housing has been replaced or

the governor linkage has been replaced, check the
maximum engine speed at no load. Refer to Testing
and Adjusting, “Engine Speed Check”.
End By:
a. Install the crankshaft pulley. Refer to Disassembly

and Assembly, “Crankshaft Pulley - Remove and
Install”.
b. Install the fuel injection pump. Refer to

Disassembly and Assembly, “Fuel Injection Pump
- Install”.
i02187994
Crankcase Breather - Remove

and Install
Removal Procedure (Naturally

Aspirated Engines)
NOTICE g01114038
Illustration 87
Typical example
component life. 1. Remove the setscrews (1) and remove the
breather cover (2) from the valve mechanism
cover (10).
NOTICE
Care must be taken to ensure that fluids are contained 2. Remove the spring (3). Remove the diaphragm
during performance of inspection, maintenance, test- assembly (4).
to collect the fluid with suitable containers before 3. Clean the vent hole (6). Clean the cavity (5) for
opening any compartment or disassembling any com- the breather assembly in the valve mechanism
ponent containing fluids. cover (10).
Dispose of all fluids according to local regulations and 4. If necessary, remove the setscrews (7). Remove
mandates. the plate (8) and remove the gauze (9).
5. Clean all parts and inspect all parts. Replace any

The two cylinder, the three cylinder and the four
parts that are worn or damaged.
cylinder engines have different crankcase breathers.
The removal procedure is identical for all models.
Removal Procedure (Turbocharged
Engines)
NOTICE

component life.
52 SENR9973
5. If necessary, remove the setscrews (9). Remove

NOTICE the plate (10) and remove the gauze (11).
during performance of inspection, maintenance, test- 6. Clean all parts and inspect all parts. Replace any
ing, adjusting, and repair of the product. Be prepared parts that are worn or damaged.
opening any compartment or disassembling any com- Installation Procedure (Naturally
Aspirated Engines)
mandates. NOTICE

component life.
NOTICE
Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working properly.
The two cylinder, the three cylinder and the four

cylinder engines have different crankcase breathers.
The installation procedure is identical for all models.
g01114041
Illustration 88
Typical example
1. Remove the setscrews (1) and remove the

breather cover (2) from the valve mechanism
cover (12).
2. Remove the spring (3). Remove the diaphragm g01114038

Illustration 89
assembly (4).
Typical example
3. Remove the adapter (6). Remove the joint (7).
Clean the vent hole (5).
4. Clean the cavity (8) for the breather assembly in

the valve mechanism cover (12).
SENR9973 53
1. If necessary, install a new gauze (9). Apply a

bead of 1861108 POWERPART silicon jointing
compound to the mating face of the plate in the
valve mechanism cover (10). Install the plate (8).
a torque of 1.5 N·m (13 lb in).
2. Install a new diaphragm assembly (4) into cavity

(5) of the valve mechanism cover. Install a new
spring (3).
3. Install the breather cover (2) and the four

of 3 N·m (27 lb in).
(Turbocharged Engines)
NOTICE

component life.
NOTICE
Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working properly.
g01114041
Illustration 90
Typical example
1. If necessary, install a new gauze (11). Apply a

bead of 1861108 POWERPART silicon jointing
compound to the mating face of the plate in the
valve mechanism cover (12). Install the plate (10).
a torque of 1.5 N·m (13 lb in).
2. Install a new joint (7). Install the adapter (6).
Note: the connection on the adapter should face to

the rear of the engine. The vent hole (5) should face
upward.
3. Install a new diaphragm assembly (4) into the

adapter (6). Install a new spring (3).
4. Install the breather cover (2) and the four

of 3 N·m (27 lb in).
54 SENR9973
i02187972 1. Remove the setscrews (2) from the connector

(3) and remove the connector from the valve
Valve Mechanism Cover - mechanism cover (6). Remove the gasket (4).
Remove and Install Discard the gasket.
2. Remove the setscrews (1) and remove the cap

nuts (5) that attach the valve mechanism cover (6)
to the housing (7) for the rocker shaft assembly.
Removal Procedure
3. Remove the valve mechanism cover (6) from the
NOTICE housing (7) for the rocker shaft assembly. Remove
Keep all parts clean from contaminants. the joint (8) from the valve mechanism cover (6).
Inspect the joint. If the joint is worn or damaged,
Contaminants may cause rapid wear and shortened use a new part for replacement.
component life.
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
to collect the fluid with suitable containers before Contaminants may cause rapid wear and shortened
opening any compartment or disassembling any com- component life.
Note: The installation procedure is similar for the
mandates.
engine.
cylinder, the three cylinder and the four cylinder 1. Clean all surfaces thoroughly.
engine.
Note: The inlet manifold is part of the valve

mechanism cover.
g00819350
Illustration 92
Typical example
2. Install the joint (8) to the valve mechanism cover

g00819350 (6).
Illustration 91
Typical example 3. Install the valve mechanism cover (6) to the
housing (7) for the rocker shaft assembly.
SENR9973 55
4. Install the setscrews (1) and install the cap nuts

(5).
5. For 402C-05 and 403C-07 engines, tighten the

setscrews and cap nuts to a torque of 10 N·m
(7.5 lb ft).

setscrews and the cap nuts to a torque of 11 N·m
(8.1 lb ft).

tighten the setscrews and the cap nuts to a torque
of 14 N·m (10 lb ft).
6. Install a new gasket (4) to the valve mechanism

cover (6). Install the connector (3) to the valve
mechanism cover (6) with setscrews (2). Tighten
i02187973 g00827968
Illustration 93
Rocker Shaft and Pushrod - Typical example
Remove 1. Loosen the nuts and the adjustment screws (3) on

the rocker arms in order to release the tension
from the rocker shaft assembly (4).
Removal Procedure 2. Remove the nuts (2) and the setscrews (1) from
the rocker shaft assembly (4).
Start By:
3. Remove the rocker shaft assembly (4) from
a. Remove the engine oil line. Refer to Disassembly cylinder head (7).
and Assembly, “Engine Oil Line - Remove and
Install”. 4. Remove the pushrods (6) from the cylinder head.
Mark the pushrods for installation. Inspect the
b. Remove the valve mechanism cover. Refer to pushrods for wear or for damage. If the pushrods
Disassembly and Assembly, “Valve Mechanism are damaged, use new parts for replacement.
Cover - Remove and Install”.
5. Remove the caps (not shown) from the top of the
NOTICE valve stems (5). Mark the caps for installation.
Keep all parts clean from contaminants. Inspect the caps for wear or for damage. If the
caps are worn or damaged, use new parts for
Contaminants may cause rapid wear and shortened replacement.
component life.
6. Remove the joint (9) from the base of the rocker
shaft assembly (8). Inspect the joint. If the joint is
NOTICE worn or damaged, use a new part for replacement.

mandates.

engines. The illustration shows the four cylinder
engine.
56 SENR9973
i02187975 4. In order to remove the rocker shaft (4), install a

suitable setscrew with a M8 x 1.25 thread into the
Rocker Shaft - Disassemble end of the rocker shaft. Use the setscrew to pull
the rocker shaft (4) from the base of the rocker
shaft (8).
Disassembly Procedure (402C-05,

403C-07, 403C-11 and 404C-15
engines) parts propelled by a released spring force.
Start By:
ment.
a. Remove the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
NOTICE
Keep all parts clean from contaminants. 5. Remove the rocker arms (3), the washers (9), and
the springs (10).
component life. Note: Place an identification mark on each of the
components for installation.
6. Remove the adjustment screws (1) and the nuts

(2) from rocker arms (3).
7. Inspect all of the components for wear or for

damage. Refer to the Specifications Manual,
“Rocker Shaft”. If any of the components are worn
or damaged, use new parts for replacement.
Disassembly Procedure (403C-15,

404C-22 and 404C-22T engines)
Start By:
a. Remove the rocker shaft and the pushrods. Refer

NOTICE
g01124594
Illustration 94
Typical example Contaminants may cause rapid wear and shortened
component life.
1. Remove the threaded plug (6) from the base of
the rocker shaft (8).
2. Remove the O-ring (5) from the threaded plug (6).

Discard the O-ring.
3. On 403C-07, 403C-11 and 404C-15 engines,

remove the setscrew (7) that locates the rocker
shaft (4) to the base of the rocker shaft (8).
SENR9973 57
i02187976
Rocker Shaft - Assemble
Assembly Procedure (402C-05,

403C-07, 403C-11 and 404C-15
engines)
NOTICE

component life.
Note: The assembly procedure is similar for the

engines. The illustration shows a three cylinder
engine.
1. Lubricate the adjustment screw (1) with clean

engine oil. Install the adjustment screw (1) and the
nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
g01124595
Illustration 95
Typical example
1. In order to remove the rocker shaft (4), install a

suitable M8 setscrew into the end of the rocker
shaft. Use the setscrew to pull the rocker shaft (4)
from the base of the rocker shaft (5).


ment.

2. Remove the rocker arms (3), the washers (7), and g01124596
Illustration 96
the springs (8).
Typical example
Note: Place an identification mark on each of the
components for installation. 2. Lubricate the rocker shaft (4) with clean engine
oil. Position the end of the rocker shaft into the
3. Remove the O-ring (6) from the rocker shaft (4). bore in the base of the rocker shaft (8).
4. Remove the adjustment screws (1) and the nuts For 402C-05 engines, align the two recesses (not
(2) from rocker arms (3). shown) in the rocker shaft with the holes in the
base of the rocker shaft (8).
5. Inspect all of the components for wear or for
damage. Refer to the Specifications Manual, For 403C-07, 403C-11 and 404C-15 engines,
“Rocker Shaft”. If any of the components are worn align the hole (10) in the rocker shaft with the hole
or damaged, use new parts for replacement. (9) in the base of the rocker shaft (8).
58 SENR9973
3. Gradually insert the rocker shaft (4) into the base Assembly Procedure (403C-15,
of the rocker shaft (8). Install the rocker arm (3).
404C-22 and 404C-22T engines)
NOTICE
parts propelled by a released spring force. Contaminants may cause rapid wear and shortened
component life.
ment.
Note: The assembly procedure is similar for the three
Follow the recommended procedure and use all cylinder and the four cylinder engines. The illustration
recommended tooling to release the spring force. shows a four cylinder engine.
1. Lubricate the adjustment screw (1) with clean

4. Continue to insert the rocker shaft (4) and install engine oil. Install the adjustment screw (1) and the
the following components to the rocker shaft: nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
• Rocker arm (3)
• Washer (9)
• Spring (10)
• Washer (9)
• Rocker arm (3)
5. Repeat Steps 4 and 3 in order to install the
remaining components.
6. Ensure that the rocker shaft (4) is fully engaged

into the base of the rocker shaft (8). Check that
the alignment of the rocker shaft is correct.
7. For 403C-07, 403C-11 and 404C-15 engines,

apply 21820117 POWERPART Threadlock to
the first two threads of the setscrew (7). Install
the setscrew (7) in the hole (9) in the base of the
rocker shaft. Tighten the setscrew.
Note: Ensure that no 21820117 POWERPART

Threadlock is allowed to contaminate the oil gallery
in the rocker shaft.
8. Install a new O-ring (5) to the threaded plug (6).

g01113618
Illustration 97
9. Install the threaded plug (6) to the base of the
rocker shaft (9). Tighten the plug to a torque of Typical example
15 N·m (11 lb ft).
2. Install a new O-ring (8) onto the rocker shaft (4).
End By: Lubricate the rocker shaft with clean engine oil.
a. Install the rocker shaft and the pushrods. Refer to 3. Position the end of the rocker shaft (4) into the
Disassembly and Assembly, “Rocker Shaft and bore in the base of the rocker shaft (7). Align the
Pushrod - Install”. recesses (5) on the rocker shaft with the holes (6)
in the base of the rocker shaft (7).
4. Gradually insert the rocker shaft (4) into the base

of the rocker shaft (7). Install the rocker arm (3).
SENR9973 59


ment.

5. Continue to insert the rocker shaft (4) and install

the following components to the rocker shaft:
• Rocker arm (3)

• Washer (9)
• Spring (10)
• Washer (9) Illustration 98
g00827968
Typical example
• Rocker arm (3)
1. Install the joint (9) to the base of the rocker shaft
6. Repeat Steps 4 and 3 in order to install the assembly (8).
remaining components.
2. Lubricate the pushrods (6) with clean engine oil.
7. Ensure that the rocker shaft (4) is fully engaged Install the pushrods (6) in the cylinder head (7).
into the base of the rocker shaft (7). Check that Ensure that the pushrods are installed correctly in
the recesses (5) on the rocker shaft are aligned the socket of the valve lifters.
with the holes (6) in the base of the rocker shaft.
Note: If the pushrods have been used, ensure that
End By: the pushrods are installed in original positions.
a. Install the rocker shaft and the pushrods. Refer to 3. Lubricate the top of the valve stems (5) with clean
Disassembly and Assembly, “Rocker Shaft and engine oil. Install the caps (not shown) on the top
Pushrod - Install”. of the valve stems.
i02196163 Note: If the caps have been used, ensure that the
caps are installed in original positions.
Rocker Shaft and Pushrod -
4. Lubricate the adjustment screws (3) on each
Install rocker arm with clean engine oil before installation.
Install the rocker shaft assembly (4) to the cylinder
head (7).
Installation Procedure Note: Ensure that the ends of the adjustment screws
on each rocker arm are correctly seated in the ends
NOTICE of the pushrods (6).
5. Install the setscrews (1) and the nuts (2).
component life. 6. Evenly tighten the setscrews (1) and the nuts (2).
Note: The tightening sequence moves from the

Note: The installation procedure is similar for the center of the rocker shaft outward.
engines. The illustrations show the four cylinder 7. For 402C-05 and 403C-07 engines, tighten the
engine. fasteners to a torque of 10 N·m (7.4 lb ft).
60 SENR9973

nuts (1) and the setscrews (2) to a torque of NOTICE
23 N·m (17 lb ft). Keep all parts clean from contaminants.
For 403C-15, 404C-22 and 404C-22T engines, Contaminants may cause rapid wear and shortened
tighten the nuts (1) and the setscrews (2) to a component life.
8. Adjust the valve lash. Refer to Testing and NOTICE

Adjusting, “Engine Valve Lash - Inspect/Adjust” for Care must be taken to ensure that fluids are contained
the correct procedure to adjust the valve lash. during performance of inspection, maintenance, test-
End By: to collect the fluid with suitable containers before
a. Install the valve mechanism cover. Refer to ponent containing fluids.
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”. Dispose of all fluids according to local regulations and
mandates.
b. Install the engine oil line. Refer to Disassembly
and Assembly, “Engine Oil Line- Remove and
Install”.
i02187979
Cylinder Head - Remove
Removal Procedure
Start By:
a. Remove the water pump. Refer to Disassembly Illustration 99

g00828137
and Assembly, “Water Pump - Remove”.
Typical example
b. Remove the exhaust manifold. Refer to

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

d. Remove the rocker shaft and the pushrods. Refer

e. Remove the fuel injection lines. Refer to

- Remove and Install”. g01116726
Illustration 100
f. Remove the fuel injectors. Refer to Disassembly Typical example for the 2 cylinder head
and Assembly, “Fuel Injectors - Remove”.
g. Remove the oil line. Refer to Disassembly and

Assembly, “Engine Oil Line - Remove and Install”.
SENR9973 61
3. Remove the cylinder head gasket from the cylinder

block (3) or the cylinder head (2). Do not reuse the
old cylinder head gasket for the cylinder head (2).
Note: Place the cylinder head on a surface that will

not scratch the face of the cylinder head.
Note: The old gasket for the cylinder head should

be used for identification. Head gaskets of different
thickness are available. Refer to Specifications,
“Cylinder Head”. The piston height relative to the
cylinder head is controlled by the thickness of
the head gasket. Refer to Testing and Adjusting,
“Cylinder Head - Inspect”.
g00854316
Illustration 101 4. If necessary, remove the cylinder head dowels
Typical example for the 3 cylinder head from the cylinder block (3). Use a suitable puller to
remove the cylinder head dowels.
5. Inspect the cylinder head (2). Refer to Testing and

Adjusting, “Cylinder Head - Inspect” and Testing
and Adjusting, “Valve Depth - Inspect”.
i02187980
Cylinder Head - Install
g01109567
Illustration 102 NOTICE
Typical example for the 4 cylinder head Keep all parts clean from contaminants.
1. Loosen the cylinder head bolts (1) in reverse order Contaminants may cause rapid wear and shortened
as this will help prevent distortion of the cylinder component life.
head (2).
For the 402C-05 engine, gradually loosen the

cylinder head bolts (1) in the reverse order that is
shown in illustration 100.
For the 403C-07, 403C-11 and 403C-15 engines,

gradually loosen the cylinder head bolts (1) in the
reverse order that is shown in illustration 101.

gradually loosen the cylinder head bolts (1) in the
reverse order that is shown in illustration 102.
Note: Do not use a pry bar to separate the cylinder

head from the cylinder block . Use a rubber mallet to Illustration 103
g00828137
loosen the cylinder head from the cylinder block.
Typical example
2. Attach a suitable lifting device to the cylinder

1. Thoroughly clean the top of cylinder block (3) and
head (2). Carefully lift the cylinder head (2) off the
the bottom of the cylinder head (2). Ensure that
cylinder block (3).
there is no debris in the cylinder bores.
Note: Avoid contamination of the cylinder bores with
2. If necessary, install the dowels (6) to the cylinder
coolant or with debris.
block (3).
62 SENR9973
g00828396 g01116726
Typical example Typical example for the 2 cylinder head
3. Install suitable guide studs (not shown) to the

cylinder block (3). Place the cylinder head gasket
(4) over the guide studs and align the gasket (4)
with the dowels (6) in the cylinder block (3).
Note: The old gasket for the cylinder head should

be used for identification. Head gaskets of different
thickness are available. Refer to Specifications,
“Cylinder Head”. The piston height relative to the
cylinder head is controlled by the thickness of
the head gasket. Refer to Testing and Adjusting,
“Cylinder Head - Inspect”.
Note: A four digit number is stamped on cylinder

g00854316
head gasket (4) at location (5). This number should Illustration 106
face the cylinder head in order to ensure the correct Typical example for the 3 cylinder head
positioning of the cylinder head gasket. Do not use
any gasket sealant or compound on the cylinder
head gasket.
4. Attach a suitable lifting device to the cylinder head

(2).
5. Install the cylinder head (2) to the cylinder block

(3). Check that the cylinder head is positioned
correctly.
6. Lubricate the cylinder head bolts (1) with clean

engine oil.
g01109567
Illustration 107
Typical example for the 4 cylinder head
7. Install the cylinder head bolts (1) finger tight.
For 402C-05 engines, tighten the cylinder head

bolts to a torque of 36.5 N·m (26.9 lb ft). Use the
numerical sequence that is shown in illustration
105.
SENR9973 63
For 403C-07 engines, tighten the cylinder head i02187977

numerical sequence that is shown in illustration Lifter Group - Remove and
106. Install
numerical sequence that is shown in illustration
106. Removal Procedure
For 403C-15 engines, tighten the cylinder head Start By:
numerical sequence that is shown in illustration a. Remove the cylinder head assembly. Refer to
106. Disassembly and Assembly, “Cylinder Head -
Remove”.
bolts to a torque of 50.5 N·m (37.2 lb ft). Use the NOTICE
numerical sequence that is shown in illustration Keep all parts clean from contaminants.
107.
For 404C-22 and 404C-22T engines, tighten the component life.
cylinder head bolts to a torque of 100.5 N·m
(74.1 lb ft). Use the numerical sequence that is
shown in illustration 107. Note: Mark the original location of the lifters for later
installation.
End By:
a. Install the rockershaft and pushrods. Refer to

Disassembly and Assembly, “ Rockershaft and
Pushrods - Remove and Install”.
b. Install the valve mechanism cover. Refer to

c. Install the water pump. Refer to Disassembly and

Assembly, “Water Pump - Install”.
d. Install the oil line. Refer to Disassembly and

Assembly, “Engine Oil Line - Remove and Install”.
e. Install the exhaust manifold. Refer to Disassembly

and Assembly, “Exhaust Manifold - Remove and
Install”.
f. Install the fuel injectors. Refer to Disassembly and

g01110885
Assembly, “Fuel Injectors - Remove and Install”. Illustration 108
Typical example
g. Install the fuel injection lines. Refer to Disassembly
and Assembly, “Fuel Injection lines - Remove and 1. Use a suitable telescopic magnet (1) to remove
Install”. the lifter (2) from the cylinder block.
2. Inspect the lifter (2) for wear or damage. If the

lifter (2) is worn or damaged, use a new part for
replacement.
3. Repeat Steps 1 and 2 for the remaining lifters.

64 SENR9973
Installation Procedure c. Remove the fuel priming pump. Refer to

Disassembly and Assembly, “Fuel Priming Pump -
NOTICE Remove”.
NOTICE
Contaminants may cause rapid wear and shortened Keep all parts clean from contaminants.
component life.
component life.
NOTICE

mandates.
g01116687
Illustration 109
Typical example
1. Ensure that the lifter (2) is clean and that the oil
hole (3) in the lifter (2) is not restricted. Lubricate
the lifter (2) with clean engine oil and install the
lifter (2) in the cylinder block.
Note: Ensure that the lifters (2) are installed in the

original location. If the camshaft has been replaced,
install new lifters (2). Do not install worn lifters to a
new camshaft.
2. Repeat Step 1 for the remaining lifters. g00828467

Illustration 110
Typical example
End By:
a. Install the cylinder head assembly. Refer to 1. Remove the slider (1) from the camshaft gear (4).
Disassembly and Assembly, “Cylinder Head -
Install”. 2. Before the idler gear is removed, rotate the
crankshaft until the timing marks (2) on the
following components are aligned.
i02189017
• Crankshaft gear (3)
Camshaft - Remove
• Camshaft gear (4)
• Idler gear (5)
Removal Procedure
3. Remove the idler gear (5). Refer to Disassembly
Start By: and Assembly, “Engine Oil Pump - Remove”.
a. Remove the lifters. Refer to Disassembly and

Assembly, “Lifter Group - Remove and Install”.
b. Remove the engine front housing. Refer to

Remove”.
SENR9973 65
6. Carefully remove the camshaft assembly (10)

from the cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft
bearings.
7. Inspect the components for wear or damage.

Refer to specifications, “Camshaft” for details of
the camshaft lobes. Replace any components that
are worn or damaged.
i02196165
Camshaft - Disassemble
g00828468
Illustration 111
Typical example
4. Rotate the camshaft gear (4) in order to align
the access hole (8) in the camshaft gear with the Start By:
fastener for the camshaft retainer (9).
a. Remove the camshaft assembly. Refer to
Note: The two cylinder and the three cylinder engines Disassembly and Assembly, “Camshaft -
have a different type of camshaft retainer (9) to the Remove”.
four cylinder engines. The removal procedure is
identical for all models. NOTICE
For 402C-05, 403C-07, 403C-11, 403C-15 and
404C-15 engines, remove the outer setscrew (6) Contaminants may cause rapid wear and shortened
and remove the allen head screw (7). component life.
For 404C-22 and 404C-22T engines, remove the
outer setscrew (6) and remove the setscrew (7)
from the camshaft retainer (9).
5. Remove the camshaft retainer (9).
g01113616
Illustration 113
Typical example
1. Use a suitable puller to remove the camshaft gear

(5) from the camshaft (1).
g01129576
Illustration 112
Typical example Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
governor flyweights during disassembly.
66 SENR9973
2. Remove the spacer (4) and the woodruff key (2) Note: Ensure that the camshaft bearing (3) is
from the camshaft (1). installed in the correct orientation. The camshaft
bearing should be pressed squarely onto the
3. Use a suitable puller to remove the front camshaft camshaft or damage to the bearing may occur.
bearing (3) from the camshaft (1).
2. Install the spacer (4) and the woodruff key (2) to
Note: Identify the orientation of the camshaft bearing the camshaft (1).
(3) for installation.
3. Align the camshaft gear (5) with the woodruff key
4. Inspect all of the components for wear or damage. (2) on the camshaft (1). Use a suitable press to
Replace any components that are worn or install the camshaft gear to the camshaft.
damaged.
Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
i02196164
governor flyweights during installation.
Camshaft - Assemble End By:
a. Install the camshaft assembly. Refer to

Disassembly and Assembly, “Camshaft - Install”.
Assembly Procedure
i02189021
NOTICE
Keep all parts clean from contaminants. Camshaft - Install
component life.
NOTICE

component life.
1. Ensure that the camshaft is clean. Lubricate the

camshaft with clean engine oil.
g01113616
Illustration 114
Typical example
1. Ensure that the camshaft (1) is clean. Lubricate

the front end of the camshaft with clean engine oil.
Use a suitable press to install the front camshaft
bearing (3) to the camshaft.
g01129587
Illustration 115
SENR9973 67
2. Carefully install the camshaft assembly (10) into • Crankshaft gear (3)
the engine cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft • Camshaft gear (4)
bearings.
• Idler gear (5)
Number one piston will now be in the top dead
center position.
6. Install the slider (1) to the camshaft (4).
Note: Ensure that the notch on the base of the slider

(1) is engaged on the pin of the camshaft gear (4).
End By:
a. Install the engine front housing. Refer to

Install”.
g00828468
Illustration 116
Typical example b. Install the fuel priming pump. Refer to Disassembly
and Assembly, “Fuel Priming Pump - Install”.
3. Install the camshaft retainer (9).
c. Install the lifters. Refer to Disassembly and
Note: The two cylinder and the three cylinder engines Assembly, “Lifter Group- Remove and Install”.
have a different camshaft retainer (9) and fasteners
(6) and (7), to the four cylinder engines. The removal
i02186340
procedure is similar for all models.
Engine Oil Pan - Remove and
4. Align the holes in the camshaft retainer (9) with
the holes in the cylinder block (11). Install
For 402C-05, 403C-07, 403C-11, 403C-15 and
404C-15 engines, install the outer setscrew (6)
and install the allen head screw (7). Removal Procedure
For 404C-22 and 404C-22T engines, install the
NOTICE
setscrews (6) and (7).
Torque both fasteners to 11 N·m (8 lb ft).
component life.
NOTICE

mandates.
Illustration 117
g00828467 Note: The two cylinder, the three cylinder and the
four cylinder engines have different engine oil pans.
5. Install the idler gear (5). Refer to Disassembly and The removal procedure is identical for all models.
Assembly, “Engine Oil Pump - Install”.
Note: When you install the idler gear, ensure

that timing marks (2) are aligned on the following
components.
68 SENR9973
g00820013 g00820013
1. Remove the drain plugs (5) from the engine oil pan 1. Clean all surfaces thoroughly.
(2). Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and 2. Install a new joint (1) to the engine. Install the
Maintenance Manual, “Refill Capacities” for the engine oil pan (2) to the engine.
approximate capacity of the lubricating oil system.
3. Install the setscrews (4) for the engine oil pan (2).
2. Remove the sealing washers (3) from the drain Tighten the setscrews for the engine oil pan to a
plugs (5). Discard the sealing washers. torque of 11 N·m (8 lb ft).
3. Remove the setscrews (4) for the engine oil pan 4. Install the drain plugs (5) and new sealing washers
(2). (3) to the oil pan (2). Tighten the drain plugs to a
4. Remove the engine oil pan (2) from the engine.
5. Fill the engine oil pan to the correct level that
5. Remove the joint (1) from the engine oil pan and is indicated on the engine oil level gauge. Refer
the cylinder block. Discard the joint. to Operation and Maintenance Manual, “Refill
Capacities” for more information.
i02189003
NOTICE
Keep all parts clean from contaminants. Pistons and Connecting Rods
- Remove
component life.
Note: The two cylinder, the three cylinder and the Removal Procedure
four cylinder engines have different engine oil pans.
The installation procedure is identical for all models. Start By:
a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.
b. Remove the engine oil pan. Refer to Disassembly

Install”.
c. Remove the oil suction pipe. Refer to Disassembly

and Assembly, “Engine Oil Pump - Remove”.
SENR9973 69
8. Keep connecting rods (1) and connecting rod caps

NOTICE (5) together. Ensure that the identification marks
Keep all parts clean from contaminants. are on the connecting rod and on the connecting
rod cap. This will ensure that the piston is installed
Contaminants may cause rapid wear and shortened into the correct cylinder in the cylinder block.
component life.
9. Repeat Steps 1 through 8 for removing the
remaining pistons and connecting rods.
1. Position the piston that is being removed in the
bottom center position.
i02189019
Pistons and Connecting Rods

- Disassemble
Start By:
a. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
g00829370
Illustration 120
Typical example NOTICE
Removal of the piston pin bushing must be carried
2. Remove the carbon buildup from the inner surface out by personnel with the correct training. Also spe-
of the top of the cylinder bore. cial machinery is required. For more information refer
to your authorized Perkins dealer or your Perkins dis-
3. Ensure that the connecting rod and the cap are tributor.
correctly marked to the cylinder.
Note: Do not punch the connecting rod or stamp the NOTICE

connecting rod assembly as this may cause damage. Keep all parts clean from contaminants.
4. Remove the nuts (6) from the connecting rod (1). Contaminants may cause rapid wear and shortened
component life.
5. Remove the connecting rod cap (5) with the
bearing shell (3).
Note: Use tape or rubber tubing on connecting rod

bolts (2) to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the
crankshaft journals.
6. Push the piston and connecting rod (1) away

from the crankshaft until the piston rings are out
of the cylinder bore. Remove the piston from the
cylinder block.
Note: Make a mark under the piston on the pin boss

in order to identify the cylinder. Always mark the front
pin boss to aid installation.
7. Remove connecting rod bearings (3) from

connecting rod (1) and connecting rod cap (5).
70 SENR9973
g01114004 g01114007
1. Use suitable pliers in order to remove the circlips 3. Use a suitable ring expander in order to remove
(2). the piston rings (7) and (6), and the oil control ring
(5) from the piston (4).
2. Remove the piston pin (3) from the piston (4).
Note: Identify the orientation of the piston rings for
Note: If the piston pin cannot be removed by hand, installation.
heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Do not use a oxyacetylene torch to heat
the piston. Mark the piston pin for installation.
SENR9973 71
5. Use a suitable press and a suitable adapter in

order to remove the piston pin bushing (11) from
the connecting rod (1).
i02189011

- Assemble
Assembly Procedure
NOTICE

component life.
NOTICE
Installation of the piston pin bushing must be carried
out by personnel with the correct training. Also special
machinery is required.
g01114027 1. If the piston pin bushing was removed, refer to

Illustration 123
your authorized Perkins dealer or your Perkins
Typical example distributor for assistance.
4. Remove the nuts (8) for the connecting rod cap
(9). Remove the connecting rod cap (9) from
the connecting rod (1). Remove the bearing
shells (10) from the connecting rod (1) and the
connecting rod cap (9).
g01114056
Illustration 124 g01114138
Illustration 125
Typical example
Typical example
2. Align the identification marks (2) on the connecting

rod (1) and the piston (5).
72 SENR9973
Note: The Shibaura name inside the piston must

align with the stamped number on the connecting rod.
3. Lubricate the piston pin (4) with clean engine oil.

Install the piston pin (4) into the piston (5) and the
connected rod (1).
Note: If the piston pin cannot be installed by hand,

heat the piston to a temperature of 45° ± 5°C
(113° ± 9°F).
4. Use suitable pliers to install the two circlips

(3). Ensure that the circlips are seated into the
grooves in the piston (5).
g01114373
Illustration 127
typical example
5. Use a suitable ring expander to install the piston

rings onto the piston (5). Use the following
procedure to install the piston rings onto the
piston.
a. Install the oil control ring (6) in the groove that

is lowest on the piston (5). The latch pin (10)
that is on the oil control ring (6) must be inside
the ends of spring (11).
Note: Ensure that the latch pin that is on the oil

control ring is 180 degrees from the oil control ring
gap.
g01114155
Illustration 126
Typical example
Note: Refer to Specifications, “Pistons and Rings” for

more information on piston identification.
g01114374
Illustration 128
b. Install the intermediate piston ring (7) with the

tapered face into the second groove on the
piston. The step (12) must be toward the top
of the piston.
SENR9973 73
c. Install the top piston ring (8) with the barrel

face and the molybdenum insert into the top
groove on the piston.
d. Lubricate the piston rings with clean engine oil.

Position the piston ring gaps (9) at 90 degrees
away from each other.
End By:
a. Install the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Piston and
Connecting Rods - Install”.
i02189022

- Install
g01111980
Illustration 129
Installation Procedure Typical example
NOTICE 4. Use a suitable piston ring compressor (1) in order

Keep all parts clean from contaminants. to compress the piston rings.
Contaminants may cause rapid wear and shortened For the 402C-05 and 403C-07 engines, the piston
component life. ring compressor should be suitable for a piston
67 mm (2.64 inch).
1. Thoroughly clean all of the components. For the 403C-11 and 404C-15 engines, the piston
ring compressor should be suitable for a piston
Note: Refer to Disassembly and Assembly, 77 mm (3.03 inch) in diameter.
“Connecting Rod Bearings - Install” for the inspection
procedure of the connecting rod bearings and the For the 403C-15, 404C-22 and 404C-22T engines,
crankshaft connecting rod journals. the piston ring compressor should be suitable for
a piston 84 mm (3.31 inch) in diameter.
2. Apply clean engine oil to the following components:
Note: Move the piston rings on the pistons until
• Crankshaft journals the ring openings are separated by approximately
90 degrees. Refer to Disassembly and Assembly,
• Inside of the cylinder bores “Pistons and Connecting Rods - Assemble”.
• Piston rings
• Connecting rod bearings
Note: The piston and the connecting rod are matched
to a specific cylinder. Ensure that the connecting rod
and the pistons are installed in the correct cylinder.
Note: Do not punch the connecting rod or stamp the

connecting rod assembly as this may cause damage.
3. Rotate the crankshaft until the bearing journal is

at the bottom center.
g01112036
Illustration 130
Typical example
74 SENR9973
5. Put the piston and the connecting rod in the 10. Rotate the crankshaft in order to ensure that no
cylinder bore. Align the identification marks on the binding occurs.
top of the piston to the front of the cylinder block.
Align the identification marks (3) on the side of End By:
the connecting rod to the right side of the cylinder
block. a. Install the oil suction pipe. Refer to Disassembly
and Assembly, “Engine Oil Pump- Install”.
Note: The right side is determined from the flywheel
end of the engine. b. Install the engine oil pan. Refer to Disassembly
Note: Ensure that the piston ring compressor (1) is Install”.
installed correctly in order to allow the piston and the
connecting rod to easily slip into the cylinder block. c. Install the cylinder head. Refer to Disassembly
Use tape or rubber tubing on the connecting rod bolts and Assembly, “Cylinder Head - Install”.
to protect the crankshaft journals.
i02186176
6. Align the piston and the connecting rod assembly
with the crankshaft. Use a soft faced hammer (2)
to tap the piston into the cylinder bore until the
Connecting Rod Bearings -
piston ring compressor (1) comes off the piston. Remove
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly

Install”.
b. Remove the oil supply tube. Refer to Disassembly

and Assembly, “Crankshaft - Remove”.
Illustration 131
g01116685 NOTICE
Typical example Keep all parts clean from contaminants.
7. Push the piston and the connecting rod assembly Contaminants may cause rapid wear and shortened
into the cylinder. Guide the connecting rod component life.
assembly onto the connecting rod journal.
NOTICE
8. Install the connecting rod cap (4) and the
connecting rod nuts (5).
For the 402C-05 and 403C-07 engines, tighten
the nuts (5) for the connecting rod cap (4) to a
For the 403C-11 and 404C-15 engines, tighten the
nuts (5) for the connecting rod cap (4) to a torque
mandates.
of 32 N·m (24 lb ft).
For the 403C-15, 404C-22 and 404C-22T engines, Note: The connecting rod and the connecting rod cap
tighten the nuts (5) for the connecting rod cap should have matching marks (6) on the right hand
(4)to a torque of 52 N·m (38 lb ft). side. Mark the connecting rod (1) and the connecting
rod cap (5), if necessary. The right side of the engine
9. Repeat Steps 1 through 8 for the remainder of the is determined from the flywheel end.
pistons and connecting rods.
SENR9973 75
NOTICE
When the connecting rod caps are installed, ensure
that the identification marks are aligned.
g01111763
Illustration 132
Typical example
1. Rotate the crankshaft until the piston is at the

bottom center. Remove the connecting rod nuts g01111763
(4) from the connecting rod bolts (2). Remove the Illustration 133
connecting rod cap (5) from the connecting rod (1). Typical example
2. Remove the lower bearing shell (3) of the 1. Check the clearance between the connecting rod
connecting rod bearing from the connecting rod bearing and the connecting rod bearing journal of
cap (5). the crankshaft. Install the connecting rod bearings
dry when the clearance checks are made. Refer to
3. Carefully push the connecting rod (1) into the Disassembly and Assembly, “Bearing Clearance
cylinder bore. Remove the upper bearing shell (3) - Check” for information on bearing clearance
of the connecting rod from the connecting rod. checks.
Note: Use tape or rubber tubing on the connecting 2. Clean the bearing surface of the connecting rod
rod bolts to protect the crankshaft journals. The sharp (1) and the connecting rod cap (5). Ensure that the
edges of the connecting rod bolts could damage the number (6) on the connecting rod cap (5) aligns
crankshaft journals. with the number (6) on the connecting rod (1).
4. Repeat Steps 1 through 3 for the remaining 3. Clean the upper connecting rod bearing (3) and
connecting rod bearings. lubricate the bearing face with clean engine oil.
4. Clean the lower connecting rod bearing (3) and

i02186171 lubricate the bearing face with clean engine oil.
Connecting Rod Bearings - Note: Align the tabs on the back of the connecting rod
Install bearings (3) with the tab grooves in the connecting
rod (1) and the tab grooves on the connecting rod
cap (5).
5. Install the upper connecting rod bearing (3) to the

Installation Procedure connecting rod (1).
NOTICE 6. Position the connecting rod (1) against the
Keep all parts clean from contaminants. crankshaft.
Contaminants may cause rapid wear and shortened 7. Install the lower connecting rod bearing (3) in the
component life. connecting rod cap (5).
76 SENR9973
8. Install the connecting rod cap (5) in position on Crankshaft Main Bearings
the connecting rod (1) and install the nuts (4) to
the connecting rod bolts (2). Refer to Disassembly
and Assembly, “Pistons and Connecting Rods
- Install” for the correct torque of the connecting
rod nuts (4).
Note: The identification marks must face the right

hand side of the engine for the correct installation.
9. Repeat Steps 2 through 8 for the installation of the

remaining connecting rod bearings.
End By:
a. Install the oil supply tube. Refer to Disassembly

and Assembly, “Crankshaft - Install”.
b. Install the engine oil pan. Refer to Disassembly

Install”.
g00830378
i02180881 Illustration 134
Crankshaft Main Bearings - Note: Mark the halves of the main bearing carriers
Remove for later installation.
1. Remove the setscrews (1) that secure the upper

half of main bearing cap (2) to the lower half of
main bearing cap (7).
Removal Procedure
2. Separate the upper half of main bearing cap (2)
Start By: from the lower half of main bearing cap (7).
a. Remove the crankshaft. Refer to Disassembly and Note: Dowels (5) are installed in each bearing cap
Assembly, “Crankshaft - Remove”. in order to align the two halves of the main bearing
carrier.
NOTICE
Keep all parts clean from contaminants. Note: Thrust washers are only installed on the
403C-15, 404C-22 and 404C-22T engines.
component life. 3. For 403C-15 engines, remove the lower thrust
washers (3).
For 404C-22 and 404C-22T engines, remove the

lower thrust washers (3) and the upper thrust
washer (6).
4. Remove the main bearings (4) from the main

bearing caps.
Crankshaft Bearing (Front)

Table 8

27610275 Driver Gp 1
SENR9973 77
1. Install the main bearings (4) into the halves of the

main bearing caps.
2. Position the upper half of the main bearing cap (2)

in position on the crankshaft. Position the lower
half ofthe main bearing cap (7) in position on the
crankshaft.
Note: Refer to the identification marks that have

been made on the main bearing carriers for correct
alignment.
Note: Ensure that the dowels (5) are in the correct

position. This will ensure that the two halves of the
main bearing caps are aligned.
Note: Ensure that the lubricating oil holes align with

the oil feed holes in the cylinder block.
Note: Thrust washers are only installed to 403C-15,

404C-22 and 404C-22T engines.
g01107352
Illustration 135
3. For 403C-15 engines, install the two lower thrust
1. Remove the bush for the crankshaft (1). Use washers (3).
Tooling (2) and a hammer to drive out the bush for
the crankshaft (1) from the inside of the cylinder For 404C-22 and 404C-22T engines, install the
block (3). two lower thrust washers (3) and the upper thrust
washer (6).
i02187995 Note: Ensure that the thrust washers are aligned

correctly and that the oil grooves are facing the
Crankshaft Main Bearings - crankshaft.
Install
4. Install the setscrews (1).
For the 402C-05, 403C-07, 403C-11, 403C-15

and 404C-15 engines, tighten the setscrews to a
Installation Procedure torque of 23 N·m (17 lb ft).
Crankshaft Main Bearings For the 404C-22 and 404C-22T engines, tighten
Bush for the Crankshaft (Front)

Table 9
Required Tools
27610275 Driver Gp 1
g00830378
Illustration 136
78 SENR9973
c. Remove the housing for the crankshaft rear seal.

Refer to Disassembly and Assembly, “Crankshaft
Rear Seal - Remove”.
d. Remove the engine oil pump. Refer to

Disassembly and Assembly, “Engine Oil Pump -
Remove”.
e. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
NOTICE

component life.
g01107393
Illustration 137
1. Install the bush for the crankshaft (1). Use Tooling

(6) and a hammer to drive in the bush for the
crankshaft (1) from the outside of the cylinder
block (5).
Note: Ensure that the oil supply hole (4) is aligned

with the oil gallery in the cylinder block (5).
Note: Ensure that the chamfered side (3) of the bush

for the crankshaft (1) is facing toward the cylinder
block (5) and that the joint (2) of the bush for the
crankshaft (1) is facing toward the top of the cylinder
block (5).
End By:
a. Install the crankshaft. Refer to Disassembly and

Assembly, “Crankshaft - Install”.
i02192828
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the engine oil relief valve. Refer to

Disassembly and Assembly, “Engine Oil Relief
Valve - Remove and Install”.
b. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove and Install”.
SENR9973 79
g01107623
Illustration 138
Typical example
1. Remove the bolts (3) from the crankcase cross

member.
2. Remove the two allen head screws (2) that are

recessed. The allen head screws are located at
the rear of the engine.
3. Place the rear of the engine in an upward position.

Attach a suitable lifting device (1) to the crankshaft
and the main bearing assembly (6).
4. Lift the crankshaft (6) and the main bearing

assembly from cylinder block (5). Do not scratch
any of the finished surfaces on the crankshaft.
80 SENR9973
i02193811
Crankshaft - Install
g01109599
Illustration 139
Typical example
3. Install the two allen head screws (3) that are

NOTICE recessed. The allen head screws are located at
Ensure that the oil passages in the main bearings align the rear of the engine.
with the oil passages in the cylinder block.
Tighten the allen head screws (3) to a torque of
27 N·m (20 lb ft).
1. Lower the crankshaft and the main bearing
assembly (9) into the cylinder block (8). Do 4. Ensure that the three setscrew holes (7) in the
not scratch any of the finished surfaces on the main bearing assembly (9) are aligned to the three
crankshaft. holes (5) in the cylinder block (8).
2. Align the two setscrew holes (2) in the main Note: The third hole in the main bearing assembly
bearing assembly (9) to the two holes in the (7) is not shown.
cylinder block (6).
5. Install the three setscrews (4) in the holes in the
cylinder block (5).
SENR9973 81
For the 402C-05, 403C-07, 403C-11 and 404C-15 i01996219

engines, tighten the setscrews (4) to a torque of
27 N·m (20 lb ft). Bearing Clearance - Check
tighten the setscrews (4) to a torque of 52 N·m
(38 lb ft). Measurement Procedure
6. Check the crankshaft for end play. Force the Table 10
crankshaft toward the front of the engine and Required Tools
insert a feeler gauge between the rear thrust
washer and the crankshaft. Alternatively, install a Part Description Qty
dial indicator to one end of the crankshaft. Force
the crankshaft to the front of the engine and then
force the crankshaft to the rear of the engine. Plastic Gauge (Green)
Record the variation on the dial indicator. Refer 0.025 to 0.076 mm 1
to Specifications, “Crankshaft” for the maximum (0.001 to 0.003 inch)
permissible crankshaft end play. Plastic Gauge (Red)
0.051 to 0.152 mm 1
End By: (0.002 to 0.006 inch)
Plastic Gauge (Blue)
a. Install the pistons and the connecting rods. Refer 0.102 to 0.229 mm 1
to Disassembly and Assembly, “Pistons and (0.004 to 0.009 inch)
Connecting Rods - Install”.
Plastic Gauge (Yellow)
b. Install the engine oil pump. Refer to Disassembly 0.230 to 0.510 mm 1
and Assembly, “Engine Oil Pump - Install”. (0.009 to 0.020 inch)
c. Install the housing for the crankshaft rear seal. NOTICE

Refer to Disassembly and Assembly, “Crankshaft Keep all parts clean from contaminants.
Rear Seal - Install”.
d. Install the flywheel. Refer to Disassembly and component life.
Assembly, “Flywheel - Install”.
e. Install the engine oil relief valve. Refer to Note: Perkins does not recommend the checking of
Disassembly and Assembly, “Engine Oil Relief the actual bearing clearances particularly on small
Valve - Remove and Install”. engines. This is because of the possibility of obtaining
inaccurate results and the possibility of damaging the
bearing or the journal surfaces. Each Perkins engine
bearing is quality checked for specific wall thickness.
Note: The measurements should be within

specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, the use of Plastic Gauge is an
acceptable method. Plastic Gauge is less accurate
on journals with small diameters if clearances are
less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
The technician must be very careful to use Plastic

Gauge correctly. The following points must be
remembered:
82 SENR9973
• Ensure that the backs of the bearings and the Note: When the Plastic Gauge is used, the readings
bores are clean and dry. can sometimes be unclear. For example, all parts of
the Plastic Gauge are not the same width. Measure
• Ensure that the bearing locking tabs are properly the major width in order to ensure that the parts are
seated in the tab grooves. within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
• The crankshaft must be free of oil at the contact Specifications Manual, “Main Bearing Journal” for the
points of the Plastic Gauge. correct clearances.
1. Put a piece of the Plastic Gauge on the crown of

i02193909
the bearing that is in the cap.
Note: Do not allow the Plastic Gauge to extend over

Coolant Temperature Switch -
the edge of the bearing. Remove and Install
2. Use the correct torque-turn specifications in order
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing Removal Procedure (403C-11,
when the cap is installed.
403C-15, 404C-15, 404C-22, and
Note: Do not turn the crankshaft when the Plastic 404C-22T Engines)
Gauge is installed.
3. Carefully remove the cap, but do not remove NOTICE

the Plastic Gauge. Measure the width of the Keep all parts clean from contaminants.
Plastic Gauge while the Plastic Gauge is in the
bearing cap or on the crankshaft journal. Refer Contaminants may cause rapid wear and shortened
to Illustration 140. component life.
NOTICE

mandates.
1. Drain the coolant from the cooling system into

a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
“Maintenance Section”.
g00953605
Illustration 140
Typical Example
4. Remove all of the Plastic Gauge before you install

the bearing cap.
SENR9973 83
g00830643 g01121721
2. Remove the coolant temperature switch (1) from 2. Remove the coolant temperature switch (1) from
the water temperature regulator housing (2). the water pump housing (2).
3. Clean the coolant temperature switch. Inspect 3. Clean the coolant temperature switch. Inspect
the coolant temperature switch (1) for damage. If the coolant temperature switch (1) for damage. If
the coolant temperature switch is damaged, use the coolant temperature switch is damaged, use
a new part for replacement. For information on a new part for replacement. For information on
testing the coolant temperature switch for correct testing the coolant temperature switch for correct
operation, refer to Testing and Adjusting, “Coolant operation, refer to Testing and Adjusting, “Coolant
Temperature Switch - Test”. Temperature Switch - Test”.
Removal Procedure (402C-05, and Installation Procedure (403C-11,

403C-07 Engines) 403C-15, 404C-15, 404C-22, and
404C-22T Engines)
NOTICE
NOTICE
component life.
component life.
NOTICE

mandates.
1. Drain the coolant from the cooling system into

a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
“Maintenance Section”. g00830643
Illustration 143
Typical example
1. If a used coolant temperature switch is installed,

apply 21820122 POWERPART Pipe sealant to
the threads of the coolant temperature switch (1).
2.
84 SENR9973
3. Install the coolant temperature switch (1) into the i02195380

water temperature regulator housing. Tighten
the coolant temperature switch (1) to a torque of Engine Oil Pressure Switch -
27 N·m (20 lb ft). Remove and Install
Manual, “Refill Capacities” for additional
information. Removal Procedure
NOTICE
Installation Procedure (402C-05, Keep all parts clean from contaminants.
and 403C-07 Engines)
NOTICE component life.
NOTICE
Contaminants may cause rapid wear and shortened Care must be taken to ensure that fluids are contained
component life. during performance of inspection, maintenance, test-

mandates.
Note: The engine oil pressure switch can be located

in one of two positions. The oil pressure switch can
be located in the valve mechanism cover (1), or in
the cylinder block (2). Refer to Specifications Manual,
“Engine Oil Pressure Switch” for the correct location.
g01121721
Illustration 144
Typical example
1. If a used coolant temperature switch is installed,

apply 21820122 POWERPART Pipe sealant to
the threads of the coolant temperature switch (1).
2. Install the coolant temperature switch (1) into

the water pump housing (2). Tighten the coolant
temperature switch (1) to a torque of 27 N·m
(20 lb ft).

Manual, “Refill Capacities” for additional
information.
SENR9973 85
g01130227 g01130227
1. If the oil pressure switch is located in the valve 1. If a used engine oil pressure switch is installed,
mechanism cover, remove the engine oil pressure apply a thin layer of 21820122 POWERPART
switch. Pipe sealant to the threads of the engine oil
pressure switch.
If the oil pressure switch is located in the cylinder
block, remove the engine oil pressure switch 2. If the oil pressure switch is located in the valve
and adapter assembly. Remove the engine oil mechanism cover, install the engine oil pressure
pressure switch from the adapter. switch (1). Tighten the oil pressure switch to a
torque of 11 N·m (8.1 lb ft).
2. Clean the oil pressure switch.
Installation Procedure If the oil pressure switch is located in the cylinder

block (2), install the engine oil pressure switch
Note: The engine oil pressure switch can be located
in one of two positions. The oil pressure switch can to the adapter. Tighten the engine oil pressure
switch to a torque of 23 N·m (16.9 lb ft). Install the
be located in the valve mechanism cover (1), or in
adapter and oil pressure switch assembly to the
the cylinder block (2). Refer to Specifications Manual,
“Engine Oil Pressure Switch” for the correct location. cylinder block. Tighten the adapter to a torque of
11 N·m (8.1 lb ft).
86 SENR9973
i02195432
Glow Plugs - Remove and

Install
Removal Procedure
Start By:
a. Remove the fuel injection lines, if necessary. Refer

to Disassembly and Assembly, “Fuel Injection
Lines - Remove and Install”.
g00820321
Illustration 148
Typical example
Disconnect batteries before performance of any 1. Install the glow plugs (4) in the cylinder head.
service work.
For the 402C-05,402C-07,403C-11 and 404C-15
engines, tighten the glow plugs to a torque of
NOTICE 11.5 N·m (8.5 lb ft).
For the 403C-15,404C-22 and 404C-22T engines,
Contaminants may cause rapid wear and shortened tighten the glow plugs to a torque of 17.5 N·m
component life. (13 lb ft).
2. Install the bus bar (3) on the glow plugs (4).
3. Install the washers (2) and the nuts (1) on the

glow plugs (4). Tighten the nuts (1) to a torque
of 1.2 N·m (10.6 lb in).
End By:
a. Install the fuel injection lines, if necessary. Refer to

i02196372
Illustration 147
g00820321
V-Belts - Remove and Install
Typical example
1. Remove the nuts (1) and the washers (2) from the
bus bar (3) on the glow plugs (4). Removal Procedure
2. Remove the bus bar (3) from the glow plugs (4).
NOTICE
3. Remove the glow plugs (4) from the cylinder head.
Installation Procedure component life.
NOTICE

component life.
SENR9973 87
1. Check the condition of the V-belt (5). If the

V-belt is worn or damaged, use a new V-belt for
replacement.
2. Install the V-belt (5) in position on the engine.
3. Slide the alternator (3) away from the engine.

Tighten the setscrew (1) and setscrew (2) to
a torque of 25.5 N·m (18.8 lb ft). Tighten the
fasteners (4) to a torque of 25.5 N·m (18.8 lb ft) for
the alternator (3). Refer to Testing and Adjusting,
“Belt Tension Chart” for more information on the
correct belt tension.
i02197917
Fan - Remove and Install
Illustration 149
g01109566 Removal Procedure (404C-22 and
Typical example 404C-22T Engines)
1. Loosen setscrew (1) and setscrew (2). Loosen the Start By:
fasteners (4) on the alternator (3).
a. Remove the V-Belts. Refer to Disassembly and
2. Push the alternator (3) toward the engine and Assembly, “V-Belts - Remove and Install”.
remove the V-belt (5).
NOTICE

component life.
g01109566
Illustration 150
Typical example
88 SENR9973
g01110541
Illustration 151
Typical example
1. Remove the four setscrews (1) from the fan (2)

and remove the fan (2) from the adapter (4).
2. Remove the four allen head screws (3) that secure

the adapter (4) and the pulley (5) to the water
pump (6).
3. Remove the adapter (4) and the pulley (5) from

the water pump (6).
Removal Procedure (402C-05,

403C-07, 403C-11, 403C-15 and
404C-15 Engines)
Start By:

SENR9973 89
g01116343
Illustration 152
Typical example
1. Remove the four setscrews (1) that secure the fan

(2), the spacer (3) and the pulley (4) to the water
pump (5).
2. Remove the fan (2), the spacer (3) and the pulley
(4) from the water pump (5).
90 SENR9973

and 404C-22T Engines)
g01110541
Illustration 153
Typical example
1. Install the pulley (5) and the adapter (4) in position

on the water pump (6) and ensure that the
setscrew holes are aligned.
2. Install the four allen head screws (3) in position

on the adapter (4) and align the setscrews with
the setscrew holes in pulley (5) and the setscrew
holes in the water pump (6). Tighten the four allen
head screws (3) to a torque of 10 N·m (7 lb ft).
3. Position the fan (2) so that the setscrew holes

align with the setscrew holes in adapter (4).
4. Install the four setscrews (1) onto the fan (2) and
hand tighten the setscrews.
5. Tighten the four setscrews (1) to a torque of

11 N·m (8 lb ft).
End By:
a. Install the V-Belts. Refer to Disassembly and

Assembly, “V-Belts - Remove and Install” .
SENR9973 91
Installation Procedure (402C-05,

403C-07, 403C-11, 403C-15 and
404C-15 Engines)
g01116343
Illustration 154
Typical example
1. Install the pulley (4), the spacer (3) and the fan (2) i02196771
in position on the water pump (5) and ensure that
the setscrew holes are aligned. Alternator - Remove and Install
2. Install the four setscrews (1) into the fan (2), the
spacer (3) and the pulley (4) and hand tighten the
setscrews. Removal Procedure for the 14 AMP
3. Tighten the four setscrews to a torque of 11 N·m Alternator
(8 lb ft).
Start By:
End By:
a. Install the V-Belts. Refer to Disassembly and Assembly, “V-Belts - Remove and Install”.
Assembly, “V-Belts - Remove and Install” .
Note: Disconnect all electrical connections to the
alternator before proceeding. Mark the connections
or identify the connections for future installation.
92 SENR9973
g01122900
Illustration 155
Typical example
1. Remove the bolt (1), the washer (3) and the nut
(4) from the alternator (2).
2. Remove the setscrew (5) that fastens the

alternator (2) to the engine.
3. Remove the alternator (2) from the engine.
Removal Procedure for the 15 AMP

Alternator
Start By:


SENR9973 93
g01122906
Illustration 156
Typical example
(4) from the alternator (2).
2. Remove the setscrew (5) that fastens the

alternator (2) to the engine.

Alternator
Start By:


94 SENR9973
g01122919
Illustration 157
Typical example
1. Remove the setscrew (6), the washer (5) and the

spacer (1) from the alternator (2).
2. Remove the setscrew (4) and the washer (3) that

fastens the alternator (2) to the engine.

Alternator
Start By:


SENR9973 95
g01110800
Illustration 158
Typical example
1. Remove the setscrew (1) and the washer (2) from

the alternator (3).
2. Remove the two bolts (6), the two washers (5)

and the two nuts (4) that fasten the alternator (3)
to the engine.

and the 85 AMP Alternator
Start By:


96 SENR9973
g01123177
Illustration 159
Typical example
1. Remove the setscrew (2) and the washer (1) from

the alternator (3).
(6) that fastens the alternator (3) to the engine.

SENR9973 97
Installation Procedure for the 14

AMP Alternator
g01122900
Illustration 160
Typical example
1. Position the alternator (2) on the engine.
2. Install the setscrew (5) that fastens the alternator

(2) to the engine.
3. Install the bolt (1), the washer (3) and the nut (4)
to the alternator (2).
4. Hand tighten the setscrew (5), the bolt (1) and the
nut (4) on the alternator (2).
Note: When you install the alternator, ensure that the

alternator pulley is in alignment with the crankshaft
pulley within one degree.
Note: Reconnect all electrical connections to the

alternator before operating the engine.
End By:

98 SENR9973

AMP Alternator
g01122906
Illustration 161
Typical example
2. Install the setscrew (5) that fastens the alternator

(2) to the engine.
3. Install the bolt (1), the washer (3) and the nut (4)
to the alternator (2).
4. Hand tighten the setscrew (5), the bolt (1) and the
nut (4) on the alternator (2).


End By:

SENR9973 99

AMP Alternator
g01122919
Illustration 162
Typical example
2. Install the setscrew (4) and the washer (3) that

fastens the alternator (2) to the engine.
3. Install the setscrew (6), the washer (5) and the

spacer (1) to the alternator (2).
4. Hand tighten the setscrew (4) and the setscrew

(6) on the alternator (2).


End By:

100 SENR9973

AMP Alternator
g01110800
Illustration 163
Typical example
2. Install the two bolts (6), the two washers (5) and
the two nuts (4) that fasten the alternator (3) on
the engine.
3. Install the setscrew (1) and the washer (2) to the

alternator (3).
4. Hand tighten the two bolts (6), the two nuts (4)
and the setscrew (1) on the alternator (3) .


End By:

SENR9973 101

AMP and the 85 AMP Alternator
g01123177
Illustration 164
Typical example
1. Position the alternator (3) on the engine. i02180475
2. Install the bolt (4), the washer (5) and the nut (6) Electric Starting Motor -
that fastens the alternator (3) to the engine. Remove and Install
3. Install the setscrew (2) and the washer (1) to the
alternator (3).
4. Hand tighten the bolt (4), the nut (6) and the Removal Procedure
setscrew (2) on the alternator (3).
Start By:
alternator pulley is in alignment with the crankshaft a. Disconnect all electrical connections to the
pulley within one degree. electric starting motor before proceeding. Mark all
connections or identify all connections for later
Note: Reconnect all electrical connections to the installation.
End By:

102 SENR9973
For the 403C-11, 403C-15, 404C-15, 404C-22

and 404C-22T engines, the electric starter motor
is secured to the engine with bolts, washers and
nuts (not shown).
For the 402C-05 and 403C-07 engines, the

electric starter motor is secured to the engine with
setscrews and washers.
Tighten the fasteners to a torque of 50 N·m

(36.9 lb ft).
End By:
g01117494
a. Reconnect all electrical connections to the electric
Illustration 165 starting motor before you operate the engine.
Typical example
1. Remove the fasteners (1) that secure the electric

starting motor (2) to the engine.
For the 403C-11, 403C-15, 404C-15, 404C-22

and 404C-22T engines, the electric starter motor
is secured to the engine with bolts, washers and
nuts (not shown).
For the 402C-05 and 403C-07 engines, the

electric starter motor is secured to the engine with
setscrews and washers.
2. Remove the electric starting motor (2) from the

engine.
g01117494
Illustration 166
Typical example
1. Install the electric starting motor (2) in position on

the engine.
2. Install the fasteners (1) that secure the electric

starting motor (2) to the engine.
SENR9973 103
Index Section
Index
A Crankshaft - Install................................................. 80
Installation Procedure ........................................ 80
Alternator - Remove and Install ............................. 91 Crankshaft - Remove............................................. 78
Installation Procedure for the 14 AMP Removal Procedure ........................................... 78
Alternator.......................................................... 97 Crankshaft Front Seal - Install ............................... 43
Installation Procedure for the 15 AMP Installation Procedure ........................................ 43
Alternator.......................................................... 98 Crankshaft Front Seal - Remove ........................... 43
Installation Procedure for the 40 AMP Removal Procedure ........................................... 43
Alternator.......................................................... 99 Crankshaft Main Bearings - Install......................... 77
Installation Procedure for the 55 AMP Installation Procedure ........................................ 77
Alternator........................................................ 100 Crankshaft Main Bearings - Remove..................... 76
Installation Procedure for the 65 AMP and the 85 Removal Procedure ........................................... 76
AMP Alternator............................................... 101 Crankshaft Pulley - Remove and Install ................ 42
Removal Procedure for the 14 AMP Alternator.. 91 Installation Procedure ........................................ 42
Removal Procedure for the 15 AMP Alternator.. 92 Removal Procedure ........................................... 42
Removal Procedure for the 40 AMP Alternator.. 93 Crankshaft Rear Seal - Install................................ 37
Removal Procedure for the 55 AMP Alternator.. 94 Installation Procedure ........................................ 37
Removal Procedure for the 65 AMP and the 85 Crankshaft Rear Seal - Remove............................ 36
AMP Alternator................................................. 95 Removal Procedure ........................................... 36
Cylinder Head - Install ........................................... 61
B Cylinder Head - Remove ....................................... 60
Removal Procedure ........................................... 60
Bearing Clearance - Check ................................... 81
Measurement Procedure ................................... 81
D
C Disassembly and Assembly Section........................ 4
Camshaft - Assemble ............................................ 66

Assembly Procedure.......................................... 66 E
Camshaft - Disassemble ....................................... 65
Disassembly Procedure ..................................... 65 Electric Starting Motor - Remove and Install ....... 101
Camshaft - Install................................................... 66 Installation Procedure ...................................... 102
Installation Procedure ........................................ 66 Removal Procedure ......................................... 101
Camshaft - Remove............................................... 64 Engine Oil Cooler - Remove and Install ................ 23
Removal Procedure ........................................... 64 Installation Procedure ........................................ 23
Connecting Rod Bearings - Install ......................... 75 Removal Procedure ........................................... 23
Installation Procedure ........................................ 75 Engine Oil Line - Remove and Install .................... 21
Connecting Rod Bearings - Remove ..................... 74 Installation Procedure ........................................ 22
Removal Procedure ........................................... 74 Removal Procedure ........................................... 21
Coolant Temperature Switch - Remove and Engine Oil Pan - Remove and Install..................... 67
Install ................................................................... 82 Installation Procedure ........................................ 68
Installation Procedure (402C-05, and 403C-07 Removal Procedure ........................................... 67
Engines) ........................................................... 84 Engine Oil Pressure Switch - Remove and Install.. 84
Installation Procedure (403C-11, 403C-15, Installation Procedure ........................................ 85
404C-15, 404C-22, and 404C-22T Engines) ... 83 Removal Procedure ........................................... 84
Removal Procedure (402C-05, and 403C-07 Engine Oil Pump - Install ....................................... 26
Engines) ........................................................... 83 Installation Procedure ........................................ 26
Removal Procedure (403C-11, 403C-15, 404C-15, Engine Oil Pump - Remove ................................... 24
404C-22, and 404C-22T Engines) ................... 82 Removal Procedure ........................................... 24
Crankcase Breather - Remove and Install............. 51 Engine Oil Relief Valve - Remove and Install ........ 24
Installation Procedure (Naturally Aspirated Installation Procedure ........................................ 24
Engines) ........................................................... 52 Removal Procedure ........................................... 24
Installation Procedure (Turbocharged Exhaust Manifold - Remove and Install ................. 15
Engines) ........................................................... 53 Installation Procedure ........................................ 16
Removal Procedure (Naturally Aspirated Removal Procedure ........................................... 15
Engines) ........................................................... 51
Removal Procedure (Turbocharged Engines) ... 51
104 SENR9973
Index Section
F Housing (Front) - Install ......................................... 50

Fan - Remove and Install ...................................... 87 Housing (Front) - Remove ..................................... 44
Installation Procedure (402C-05, 403C-07, Removal Procedure ........................................... 44
403C-11, 403C-15 and 404C-15 Engines)....... 91
Installation Procedure (404C-22 and 404C-22T
Engines) ........................................................... 90 I
Removal Procedure (402C-05, 403C-07, 403C-11,
403C-15 and 404C-15 Engines) ...................... 88 Important Safety Information ................................... 2
Removal Procedure (404C-22 and 404C-22T Inlet and Exhaust Valve Springs - Remove and
Engines) ........................................................... 87 Install ................................................................... 17
Flywheel - Install.................................................... 35 Installation Procedure ........................................ 18
Installation Procedure ........................................ 35 Removal Procedure ........................................... 17
Flywheel - Remove................................................ 34 Inlet and Exhaust Valves - Remove and Install ..... 19
Removal Procedure ........................................... 34 Installation Procedure ........................................ 20
Flywheel Housing - Remove and Install ................ 39 Removal Procedure ........................................... 19
Installation Procedure (Engines with Flywheel
Housing and Backplate) ................................... 40
Installation Procedure (Engines with Flywheel L
Housing)........................................................... 41
Removal Procedure (Engines with Flywheel Lifter Group - Remove and Install.......................... 63
Housing and Backplate) ................................... 39 Installation Procedure ........................................ 64
Removal Procedure (Engines with Flywheel Removal Procedure ........................................... 63
Housing)........................................................... 39
Fuel Filter Base - Install........................................... 6
Installation Procedure .......................................... 6 P
Fuel Filter Base - Remove....................................... 5
Removal Procedure ............................................. 5 Pistons and Connecting Rods - Assemble ............ 71
Fuel Injection Lines - Remove and Install................ 7 Assembly Procedure.......................................... 71
Installation Procedure .......................................... 8 Pistons and Connecting Rods - Disassemble ....... 69
Removal Procedure ............................................. 7 Disassembly Procedure ..................................... 69
Fuel Injection Pump - Install ................................... 11 Pistons and Connecting Rods - Install................... 73
Installation Procedure ......................................... 11 Installation Procedure ........................................ 73
Fuel Injection Pump - Remove .............................. 10 Pistons and Connecting Rods - Remove............... 68
Fuel Injector - Install .............................................. 12
Fuel Injector - Remove .......................................... 12 R
Fuel Priming Pump - Install ..................................... 4 Rocker Shaft - Assemble....................................... 57
Installation Procedure .......................................... 4 Assembly Procedure (402C-05, 403C-07, 403C-11
Fuel Priming Pump - Remove ................................. 4 and 404C-15 engines)...................................... 57
Removal Procedure ............................................. 4 Assembly Procedure (403C-15, 404C-22 and
Fuel Shutoff Solenoid - Remove and Install ............ 9 404C-22T engines) .......................................... 58
Installation Procedure .......................................... 9 Rocker Shaft - Disassemble .................................. 56
Removal Procedure ............................................. 9 Disassembly Procedure (402C-05, 403C-07,
403C-11 and 404C-15 engines) ....................... 56
Disassembly Procedure (403C-15, 404C-22 and
G 404C-22T engines) .......................................... 56
Rocker Shaft and Pushrod - Install........................ 59
Glow Plugs - Remove and Install .......................... 86 Installation Procedure ........................................ 59
Installation Procedure ........................................ 86 Rocker Shaft and Pushrod - Remove.................... 55
H T
Housing (Front) - Assemble................................... 47 Table of Contents..................................................... 3

Assembly Procedure.......................................... 47 Turbocharger - Remove and Install ....................... 13
Housing (Front) - Disassemble.............................. 45 Installation procedure......................................... 14
Disassembly Procedure ..................................... 45 Removal procedure............................................ 13
SENR9973 105
Index Section
V-Belts - Remove and Install ................................. 86

Valve Mechanism Cover - Remove and Install...... 54
Water Pump - Install .............................................. 29

Installation Procedure (402C-05 and 403C-07
Engines) ........................................................... 30
Installation Procedure (403C-11, 403C-15,
404C-15, 404C-22 and 404C-22T Engines) .... 29
Water Pump - Remove .......................................... 28
Removal Procedure (402C-05 and 403C-07
Engines) ........................................................... 29
404C-22 and 404C-22T Engines) .................... 28
Water Temperature Regulator - Remove and
Install ................................................................... 32
Installation Procedure (402C-05 and 403C-07
engines) ........................................................... 33
Installation Procedure (403C-11, 403C-15,
404C-15, 404C-22 and 404C-22T engines)..... 34
Removal Procedure (402C-05 and 403C-07
engines) ........................................................... 32
404C-22 and 404C-22T engines)..................... 33
Water Temperature Regulator Housing - Remove and
Install ................................................................... 31
106 SENR9973
Index Section
SENR9973 107
Index Section
©2004 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.

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SENR9973

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Connecting Rod Bearings - Install ........................ 75

Contaminants may cause rapid wear and shortened

Dispose of all fluids according to local regulations and

1. Loosen the hose clamps and remove the two fuel

Fuel Filter Base - Remove

Contaminants may cause rapid wear and shortened

Note: Ensure that the camshaft lobe for the fuel

2. Install a new O-ring (3) to the fuel priming pump(1).

3. Lubricate the operating plunger of the fuel priming

4. Install the fuel priming pump (1) to the engine.

5. Install the two setscrews (4) that fasten the fuel

6. Loosely install the hose clamps to the fuel lines.

Note: The fuel inlet for the fuel priming can be

Note: Put identification marks on all the fuel lines for

2. Remove the fuel filter element (4). Refer to

3. If necessary, remove the plugs (5), the washers

4. Remove the setscrews (8) and the nuts (not

5. Remove the fuel filter base (3) from the engine.

Fuel Filter Base - Install

Note: Some fuel filters are installed by the OEM and

2. If necessary, install the fuel filter element (4)

3. If necessary, install new olives onto the fuel lines.

4. If necessary, install new inner seals (7) to the fuel

Install new washers (6) onto the plugs (5) and

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

Fuel Injection Lines - Remove

Contaminants may cause rapid wear and shortened

For engines with a flexible fuel return hose,

Note: The installation procedure is similar for the

6. Remove the nut (5) from the fuel injectors (7).

4. Tighten the nuts (5) to a torque of 27 N·m (20 lb ft).

Fuel Shutoff Solenoid -

Contaminants may cause rapid wear and shortened

6. Connect the fuel injection lines (2) to the fuel

7. Connect the fuel injection lines (2) to the fuel

8. For the 402C-05 and 403C-07 engines, tighten

For the 403C-11, 403C-15, 404C-15, 404C-22

9. Prime the fuel system. Refer to Testing and

Contaminants may cause rapid wear and shortened

Dispose of all fluids according to local regulations and

Note: The removal procedure is similar for the two

2. Install fuel shutoff solenoid (1) into the fuel

3. Reconnect electrical connection (3) to fuel shutoff

Fuel Injection Pump - Remove

a. Remove the fuel injection lines. Refer to

b. Remove the fuel shutoff solenoid. Refer to

2. Carefully raise the fuel injection pump (1) from

3. Remove the fuel injection pump (1) from the

Fuel Injection Pump - Install

b. Install the fuel injection lines. Refer to Disassembly

i02186247 Note: 402C-05 and 403C-07 engines have two seat

3. Cap all openings or plug all openings immediately

a. Remove the fuel injection lines. Refer to Fuel Injector - Install

NOTICE Installation Procedure

Contaminants may cause rapid wear and shortened NOTICE

Contaminants may cause rapid wear and shortened

Dispose of all fluids according to local regulations and

1. Clean the injector bore in the cylinder head.

2. Install new seat washers (3) into the injector bore