Dokumen - Tips Perkins 1100 Series 1104c Industrial Engine Electronicmodel Rf11 Upservice Repair Manual 1600671034

SENR9978-02 (en-us)
February 2016
Disassembly and Assembly

1104C Industrial Engine (Electronic)
RF1 1-UP (Engine)
RH1 1-UP (Engine)
RK1 1-UP (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions 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 or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
SENR9978-02 3
Table of Contents
Table of Contents Valve Mechanism Cover - Remove and Install .......74

Rocker Shaft and Pushrod - Remove ....................76
Rocker Shaft - Disassemble ................................77
Disassembly and Assembly Section Rocker Shaft - Assemble ....................................77
Rocker Shaft and Pushrod - Install........................78
Fuel Priming Pump - Remove and Install ................4 Cylinder Head - Remove......................................79
Fuel Filter Base - Remove and Install .....................5 Cylinder Head - Install .........................................80
Fuel Injection Lines - Remove ...............................7 Lifter Group - Remove and Install .........................83
Fuel Injection Lines - Install ...................................7 Camshaft - Remove and Install ............................84
Fuel Injector Cover - Remove and Install.................9 Camshaft Gear - Remove and Install ...................85
Fuel Injection Pump - Remove ...............................9 Camshaft Bearings - Remove and Install ..............86
Fuel Injection Pump - Install ................................ 11 Engine Oil Pan - Remove and Install ....................87
Fuel Injector - Remove ........................................14 Balancer - Remove (If Equipped)..........................89
Fuel Injector - Install ...........................................14 Balancer - Install (If Equipped) .............................90
Turbocharger - Remove.......................................15 Piston Cooling Jets - Remove and Install ..............92
Turbocharger - Install ..........................................16 Pistons and Connecting Rods - Remove ...............93
Exhaust Manifold - Remove and Install ................18 Pistons and Connecting Rods - Disassemble ........93
Exhaust Elbow - Remove and Install ....................19 Pistons and Connecting Rods - Assemble.............94
Inlet and Exhaust Valve Springs - Remove and Pistons and Connecting Rods - Install...................96
Install ...............................................................20 Connecting Rod Bearings - Remove .....................97
Inlet and Exhaust Valves - Remove and Install.......22 Connecting Rod Bearings - Install.........................98
Inlet and Exhaust Valve Guides - Remove and Crankshaft Main Bearings - Remove.....................99
Install ...............................................................25 Crankshaft Main Bearings - Install (Crankshaft in
Inlet and Exhaust Valve Seat Inserts - Remove and Position) ......................................................... 100
Install ...............................................................27 Crankshaft - Remove......................................... 103
Engine Oil Filter Base - Remove and Install ..........29 Crankshaft - Install ............................................ 105
Engine Oil Cooler - Remove.................................34 Crankshaft Timing Ring - Remove and Install ...... 109
Engine Oil Cooler - Install ....................................35 Crankshaft Gear - Remove and Install ................ 110
Engine Oil Relief Valve - Remove and Install (Engine Bearing Clearance - Check ................................ 111
Oil Pump) .........................................................36 Coolant Temperature Sensor - Remove and
Engine Oil Relief Valve - Remove and Install Install ............................................................. 112
(Balancer Unit for the 1104 engines only) ............37 Engine Oil Pressure Sensor - Remove and Install 113
Engine Oil Pump - Remove (Engines Without a Speed/Timing Sensor - Remove and Install ........ 114
Balancer) ..........................................................38 Boost Pressure Sensor - Remove and Install....... 115
Engine Oil Pump - Install (Engines Without a Inlet Air Temperature Sensor - Remove and
Balancer) ..........................................................39 Install ............................................................. 115
Water Pump - Remove ........................................40 Glow Plugs - Remove and Install ....................... 116
Water Pump - Disassemble .................................40 V-Belts - Remove and Install .............................. 117
Water Pump - Assemble .....................................42 Fan - Remove and Install .................................. 118
Water Pump - Install ............................................44 Fan Drive - Remove and Install .......................... 119
Water Temperature Regulator - Remove and Electronic Control Module - Remove and Install... 120
Install ...............................................................44 Voltage Load Protection Module - Remove and
Flywheel - Remove..............................................47 Install ............................................................. 121
Flywheel - Install .................................................48 Alternator - Remove .......................................... 122
Crankshaft Rear Seal - Remove ...........................49 Alternator - Install .............................................. 123
Crankshaft Rear Seal - Install...............................49 Electric Starting Motor - Remove and Install ....... 123
Crankshaft Wear Sleeve (Rear) - Remove ............51 Vacuum Pump - Remove and Install ................... 124
Crankshaft Wear Sleeve (Rear) - Install ................52 Hydraulic Pump (Steering) - Remove.................. 125
Flywheel Housing - Remove and Install ................53 Hydraulic Pump (Steering) - Install ..................... 125
Crankshaft Pulley - Remove and Install ................54
Crankshaft Front Seal - Remove ..........................55 Index Section
Crankshaft Front Seal - Install ..............................55
Crankshaft Wear Sleeve (Front) - Install................56 Index................................................................ 126
Crankshaft Wear Sleeve (Front) - Remove ............57
Front Cover - Remove and Install .........................57
Gear Group (Front) - Remove ..............................58
Gear Group (Front) - Install ..................................60
Idler Gear (Front) - Remove .................................61
Idler Gear (Front) - Disassemble ..........................63
Idler Gear (Front) - Assemble ...............................64
Idler Gear (Front) - Install.....................................65
Housing (Front) - Remove....................................67
Housing (Front) - Install .......................................68
Accessory Drive - Remove and Install ..................70
Crankcase Breather - Remove and Install ............72
4 SENR9978-02
Disassembly and Assembly Section
Disassembly and
Assembly Section
i02276712
Fuel Priming Pump - Remove

and Install
Removal Procedure
Start By:
Illustration 1 g00952432
a. Remove the assembly of the filter case and the Typical example
fuel filter element. Refer to this Disassembly
and Assembly Manual, “Fuel Filter Base - 1. Disconnect the tube assembly (5). Disconnect the
Remove and Install”.
tube assembly (6). Install dust covers onto the
Note: Put identification marks on all fuel hose connectors for the fuel priming pump.
assemblies and on all tube assemblies for installation
2. Disconnect the fuel return line from the connector
purposes. After being disconnected, plug all fuel
hose assemblies and plug all tube assemblies. This (3). Install a dust cover to the connector (3).
helps prevent fluid loss, and this helps to keep 3. Disconnect the harness assembly from the
contaminants from entering the system. connector (2).
NOTICE 4. Support the fuel priming pump. Remove the three

Keep all parts clean from contaminants. setscrews (1) and discard the rubber washers.
Remove the fuel priming pump (4).
Contaminants may cause rapid wear and shortened
component life. Installation Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Contaminants may cause rapid wear and shortened
nance, testing, adjusting and repair of the product. component life.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
Typical example
1. Clean the external surfaces of the fuel priming

pump (4). Position the fuel priming pump (4) and
install the setscrews (1) and new rubber washers.
SENR9978-02 5
2. Remove the dust covers from the fuel priming

pump. Remove the plugs from the tube
assemblies. Connect the tube assembly (5).
Connect the tube assembly (6).
3. Connect the fuel return line to the connector (3).
4. Connect the harness assembly to the connector
(2).
5. Remove the air from the fuel system. Refer to the
Operations and Maintenance Manual, “Fuel
System - Prime”.
i02259826
Fuel Filter Base - Remove and

Install
Removal Procedure Illustration 3 g01010637

Typical example
NOTICE
Keep all parts clean from contaminants.
component life.
NOTICE
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
and mandates.
Typical example
1. Place a suitable container below the filter in order

to collect the spilled fuel. Thoroughly clean the
outside surfaces of the fuel filter. Open the drain
(1) in order to drain the fuel from the filter.
2. Use a suitable strap wrench to loosen the filter
case (2). Remove the filter case (2) from the filter
head (5).
6 SENR9978-02
3. Push down against the spring pressure that is

applied to the filter element (4). Rotate the filter
element (4) counterclockwise in order to release
the filter element from the filter case (2).
4. Discard the filter element (4) and the O-ring (3).
Installation Procedure
NOTICE
component life.
Typical example
1. Thoroughly clean the inside of the filter case (2)

and thoroughly clean the lower face of the filter
head (5).
2. Inspect the thread of a new filter element (4) in
order to ensure that the thread is not damaged.
Inspect the thread of the adapter in the filter head
(5) in order to ensure that the thread is not
damaged.
3. Inspect the condition of the spring and ensure that
the spring is correctly located within the filter case
Illustration 5 g01010637 (2).
Typical example
4. Install the new filter element (4) into the filter case
(2). Push the filter element against the spring
pressure and rotate the filter element in a
clockwise direction in order to secure the filter
element within the filter case (2).
5. Lightly lubricate a new O-ring (3) with clean fuel oil.
Install the new O-ring (3) into the recess within the
filter case (2).
6. Close the drain (1).
SENR9978-02 7
7. Remove the air from the fuel system. Refer to the 1. Disconnect the fuel injection lines (2) at the fuel
Operations and Maintenance Manual, “Fuel injectors (1).
System - Prime”. Remove the suitable container
2. Disconnect the fuel injection lines (4) at the fuel
and dispose of the fuel that has drained as waste.
injection pump (6). Ensure that the connections (5)
do not turn when the fuel injection lines are
i02259827
removed.
Fuel Injection Lines - Remove
Removal Procedure
Start By:
a. Remove the cover for the fuel injectors. Refer
to this Disassembly and Assembly Manual,
“Fuel Injector Cover - Remove and Install”.
NOTICE
component life.
NOTICE
Be prepared to collect the fluid with suitable contain- Illustration 8 g01136262
ers before opening any compartment or disassem- Typical example
Dispose of all fluids according to local regulations 3. If it is necessary remove the clamps (3) for the fuel
and mandates. injection lines or loosen the clamps for the fuel
injection lines. Remove the fuel injection lines.
4. Install dust caps onto the ports of the fuel injectors
and onto the ports of the fuel injection pump.
Install dust caps onto both ends of the fuel
injection lines.
i02259934
Fuel Injection Lines - Install
NOTICE
component life.
Typical example
8 SENR9978-02
NOTICE
and mandates.
4. Loosely connect the nuts at both ends of the fuel

injection lines.
5. Ensure that each fuel injection line does not
contact any other fuel injection line or any other
engine component. Tighten the fasteners for the
clamps (3) for the fuel injection lines . Check that
the fuel injection lines are still clear of other
components.
6. Tighten the fuel injection lines (2) at the fuel
Typical example
injectors (1) to a torque of 30 N·m (22 lb ft).
1. Inspect the fuel injection lines (2 and 4) for wear 7. Tighten the fuel injection lines (4) at the fuel
and for damage. Replace any fuel injection line injection pump (6) to 30 N·m (22 lb ft). Ensure that
that is worn or any fuel injection line that is the connection (5) can not turn.
damaged.
8. Remove the air from the fuel system. Refer to the
2. Loosely install the clamps (3) for the fuel injection Operations and Maintenance Manual, “Fuel
lines. System - Prime”.
3. Remove the dust caps from the fuel injection pump
(6) and from the fuel injectors (1). Remove the
dust caps from the fuel injection lines.
SENR9978-02 9
End By:
a. Install the cover for the fuel injectors. Refer to
this Disassembly and Assembly Manual, “Fuel
Injector Cover - Remove and Install”.
i02271067
Fuel Injector Cover - Remove

and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants. Typical example
Contaminants may cause rapid wear and shortened 1. Thoroughly clean all of the inner surfaces of the
component life. cover (1) for the fuel injectors.
2. Install the cover (1).
3. Install the setscrews (2) for the cover (1). Tighten
the setscrews (2) to a torque of 9 N·m (7 lb ft).
i02262595
Fuel Injection Pump - Remove
Removal Procedure
Table 1
Required Tools
Part Number Part Name Qty

Typical example 27610032 (Timing Pin) 1
1. Thoroughly clean all of the outer surfaces of the Start By:

cover (1) for the fuel injectors.
a. Remove the fuel injection lines. Refer to this
2. Remove the setscrews (2) from the cover (1). Disassembly and Assembly Manual, “Fuel
3. Remove the cover (1). Injection Lines - Remove”.
b. Remove the crankshaft pulley. Refer to this
Installation Procedure Disassembly and Assembly Manual,
“Crankshaft Pulley - Remove and Install”.
NOTICE
Keep all parts clean from contaminants. c. Remove the front cover. Refer to this
Disassembly and Assembly Manual, “Front
Contaminants may cause rapid wear and shortened Cover - Remove and Install”.
component life.
1. Ensure that the No. 1 cylinder is at top dead center
on the compression stroke. Refer to the Testing
and Adjusting Manual, “Finding Top Center
Position for No. 1 Piston”.
10 SENR9978-02
Illustration 13 g01136992 Illustration 15 g01136756

Typical example Typical example
2. Push the timing pin (1) through the fuel injection 5. Remove the electrical connecting plug (5).
pump gear (2) and into the fuel injection pump.
3. When the timing pin is installed the fuel injection
pump can be locked.
Note: The timing pin must be a hand push fit. The
timing pin must not be forced into position.
Typical example
6. Remove the fasteners (6) for the support bracket

and remove the support bracket (7).
Typical example
4. Remove the spacer (3) and tighten the locking

screw (4) to 31 N·m (22 lb ft).
Note: Remove the timing pin (1).
SENR9978-02 11
Typical example
9. Remove the fuel injection pump and remove the O-

ring (11). Discard the O-ring.
Illustration 17 g01136966 i02270214

Typical example
Fuel Injection Pump - Install
7. Remove the setscrews and washers (8). Remove
the fuel pump gear (2).
Note: The nut (9) must not be loosened. If the nut Installation Procedure
was loosened then the timing for the fuel injection
pump will be lost. 1. Ensure that the No. 1 cylinder is at top dead center
on the compression stroke. Refer to the Testing
and Adjusting Manual, “Fuel Injection Timing -
Check”.
2. Ensure that all the mating surfaces are clean and
free from fluid.
Typical example
8. Remove the three setscrews (10) and the sealing

washers. Discard the used sealing washers.
3. Install a new O-ring (1) onto the fuel injection

pump.
12 SENR9978-02
4. Install the fuel injection pump. Install new sealing

washers onto the setscrews and install setscrews
(2). Tighten the setscrews to 22 N·m (16 lb ft).
7. When the timing pin is correctly installed the fuel

injection pump can be locked.
Note: New fuel injection pumps are supplied in the

locked position.
5. Align the support bracket (4). Tighten the fasteners

(3) by hand.
Note: The fasteners (3) must be secured after the
front cover is installed.
6. Install the timing pin (6) through the hub (7) and
into the fuel injection pump. The timing pin must
be a hand push fit.
SENR9978-02 13
Illustration 24 g01137367 Illustration 26 g01137350
8. Refer to illustration 23 . Position the fuel injection 10. Install the electrical connecting plug (11).
pump gear (5) through the timing pin and onto the
hub (7) of the fuel injection pump. Refer to
illustration 24 . Install the setscrews and washers
(8) and tighten the setscrews by hand. The fuel
injection pump gear (5) must be rotated
counterclockwise. Tighten the setscrews (8) to
25 N·m (18 lb ft). Remove the timing pin.
9. Loosen the locking screw (10). Install the spacer

(9). Tighten the locking screw to 31 N·m (22 lb ft).
14 SENR9978-02
End By:
a. Install the front cover. Refer to this
Disassembly and Assembly Manual, “Front
Cover - Remove and Install”.
b. Install the crankshaft pulley. Refer to this
Disassembly and Assembly Manual,
“Crankshaft Pulley - Remove and Install”.
c. Tighten the fasteners (3) for the support
bracket. Tighten the nut and bolt to 22 N·m
(16 lb ft). Tighten the setscrew that is installed
into the cylinder block to 44 N·m (32 lb ft).
d. Install the fuel injection lines. Refer to this
Disassembly and Assembly Manual, “Fuel
Injection Lines - Install”.
i02270820
Fuel Injector - Remove

Typical example
Removal Procedure
Start By: 3. Remove the fuel injector (4) from the cylinder
head.
a. Remove the cover for the fuel injectors. Refer
to this Disassembly and Assembly Manual, 4. Remove the O-ring seal (6) from the fuel injector
“Fuel Injector Cover - Remove and Install”. (4) and discard the O-ring.
b. Remove the fuel injection lines. Refer to this 5. Remove the seat washer (5) and discard the seat
Disassembly and Assembly, “Fuel Injection washer.
Lines - Remove”.
Note: If the original seat washer is not removed, the
NOTICE projection of the fuel injector will be incorrect when a
Keep all parts clean from contaminants. new seat washer is installed.
Contaminants may cause rapid wear and shortened i02270858

component life.
Fuel Injector - Install
NOTICE
nance, testing, adjusting and repair of the product. Installation Procedure
ers before opening any compartment or disassem- NOTICE
bling any component containing fluids. Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations Contaminants may cause rapid wear and shortened
and mandates. component life.
1. Ensure that a cap (1) is installed onto the fuel

injector in order to stop dirt from entering the fuel
injector.
2. Remove the setscrew (3). Remove the clamp (2).
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SENR9978-02 15
End By:
a. Install the fuel injection lines. Refer to this
Disassembly and Assembly, “Fuel Injection
Lines - Install”.
b. Install the cover for the fuel injectors. Refer to
this Disassembly and Assembly Manual, “Fuel
Injector Cover - Remove and Install”.
i02282009
Turbocharger - Remove
Removal Procedure
NOTICE
component life.
Typical example
NOTICE
1. Install a new seat washer (5) in the cylinder head. Care must be taken to ensure that fluids are con-
Note: If the original seat washer (5) is reused, the nance, testing, adjusting and repair of the product.
projection of the fuel injector (4) will be incorrect. Be prepared to collect the fluid with suitable contain-
2. Install a new O-ring seal (6) on fuel injector (4). bling any component containing fluids.
Install the fuel injector (4) in the cylinder head.
Note: Alignment Pin (7) must be located opposite and mandates.
clamp (2).
3. Position clamp (2) on the fuel injector (4). Install 1. Thoroughly clean the outer surfaces of the
setscrew (3). Tighten the setscrew to a torque of turbocharger (1).
35 N·m (25 lb ft). Remove the cap (1) before the 2. Loosen the hose clamps and remove the air inlet
fuel injection lines are installed. hose at the turbocharger compressor housing.
Note: Exhaust elbows are only an option for the four
cylinder engines.
3. Remove the exhaust pipe from the turbocharger

outlet or remove the exhaust pipe from the
exhaust elbow. Refer to the OEM provided
information for the correct procedure in order to
remove the exhaust pipe.
16 SENR9978-02
7. Remove the banjo bolts (5). Remove the oil supply

tube assembly (6) and the washers (7) from the
turbocharger (1). Discard the washers (7). If
necessary, remove the oil supply tube assembly
(6) from the cylinder block and discard the
washers.
8. Remove the setscrews (8). Remove the oil drain
tube assembly (9) from the turbocharger (1).
Remove the joint (10) and discard the joint. If
necessary, remove the setscrews (11) and remove
the oil drain tube assembly (9) from the cylinder
block. Discard the joint.
9. If necessary, remove the studs (12) from the
Illustration 29 g01038600 turbocharger housing.
Typical example
Note: Do not use the actuator rod of the wastegate
4. If an exhaust elbow is installed, remove the (16) to lift the turbocharger (1).
exhaust elbow. Refer to this Disassembly and
10. Remove the nuts (13). Remove the turbocharger
Assembly Manual, “Exhaust Elbow - Remove and
(1). Remove the gasket (14). Discard the gasket
Install”.
(14). If necessary, remove the studs (15) from the
5. Remove the nuts (2) and remove the exhaust exhaust manifold.
adapter (3) from the turbocharger (1).
11. Install suitable plastic plugs into the oil supply and
6. Place a suitable container below the turbocharger into the oil drain ports of the turbocharger (1).
(1) in order to collect any spillage of oil. Install suitable plastic covers to the inlet and to the
outlet of the turbocharger (1). Install suitable
plastic plugs to the oil supply tube assembly (6)
and to the oil drain tube assembly (9). Install
suitable plastic covers to the manifold ports.
i02282010
Turbocharger - Install
NOTICE
component life.
1. Remove all of the plastic plugs from all of the ports

of the turbocharger (1). Clean the mating surfaces
of the exhaust manifold and the turbocharger.
Clean the mating surfaces of the turbocharger to
the oil supply tube assembly (6) and the
turbocharger to the oil drain tube assembly (9).
2. Ensure that all of the turbocharger inlet and outlet
ports are clean and free from restrictions. The
turbocharger shaft must rotate freely.
Typical example
SENR9978-02 17
9. Position a new joint and the oil drain tube

assembly (9) onto the cylinder block. Tighten the 8
mm setscrews (11) to a torque of 22 N·m (16 lb ft).
10. Position the new washers (7) and the oil supply
tube assembly (6) onto the turbocharger (1). Install
the banjo bolt (5). Tighten the banjo bolt (5) to a
torque of 22 N·m (16 lb ft).
Note: Ensure that the oil supply tube assembly (6)
does not come into contact with any other component
when the assembly is installed onto the engine.
11. Install the new washers and the oil supply tube
assembly (6) to the cylinder block. Tighten the
banjo bolt to a torque of 22 N·m (16 lb ft).
12. If the studs (12) were previously removed, install
the studs into the turbocharger housing.
Typical example
3. If the studs (15) were previously removed, install

the studs into the exhaust manifold. Install a new
gasket (14) over the studs (15).
Note: Do not use any sealant on the gasket (14). Typical example
Note: Do not use the actuator rod of the wastegate 13. Position the exhaust adapter (3) onto the studs
(16) to lift the turbocharger (1).
(12). Install the nuts (2). Do not tighten the nuts (2)
4. Position the turbocharger (1) onto the exhaust at this time.
manifold. Note: Exhaust elbows are only an option for the four
5. Install the nuts (13). Tighten the nuts (13) to a cylinder engines.
torque of 47 N·m (35 lb ft).
14. If equipped, install the exhaust elbow onto the
6. Lubricate the bearing housing of the turbocharger exhaust adapter (3). Refer to this Disassembly
(1) with clean engine oil. and Assembly Manual, “Exhaust Elbow - Remove
and Install”.
7. Inspect all of the oil hose assemblies (6 and 9). If
necessary, replace the hose assemblies (6 and 9).
Note: The top flange of the oil drain tube assembly
(9) is secured to the turbocharger (1) with 6 mm
setscrews (8). The bottom flange of the oil drain tube
assembly (9) is secured to the cylinder block with 8
mm setscrews (11).
8. Position a new joint (10) and the oil drain tube

assembly (9) onto the bottom of the turbocharger
(1). Install the 6 mm setscrews (8). Tighten the 6
mm setscrews (8) to a torque of 9 N·m (80 lb in).

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SENR9978-02 (en-us)

Disassembly and Assembly

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Valve Mechanism Cover - Remove and Install .......74

Fuel Priming Pump - Remove

NOTICE 4. Support the fuel priming pump. Remove the three

1. Clean the external surfaces of the fuel priming

2. Remove the dust covers from the fuel priming

Fuel Filter Base - Remove and

Removal Procedure Illustration 3 g01010637

1. Place a suitable container below the filter in order

3. Push down against the spring pressure that is

1. Thoroughly clean the inside of the filter case (2)

Fuel Injection Lines - Install

4. Loosely connect the nuts at both ends of the fuel

Fuel Injector Cover - Remove

Fuel Injection Pump - Remove

Part Number Part Name Qty

1. Thoroughly clean all of the outer surfaces of the Start By:

Illustration 13 g01136992 Illustration 15 g01136756

6. Remove the fasteners (6) for the support bracket

4. Remove the spacer (3) and tighten the locking

9. Remove the fuel injection pump and remove the O-

Illustration 17 g01136966 i02270214

8. Remove the three setscrews (10) and the sealing

3. Install a new O-ring (1) onto the fuel injection

4. Install the fuel injection pump. Install new sealing

7. When the timing pin is correctly installed the fuel

Note: New fuel injection pumps are supplied in the

5. Align the support bracket (4). Tighten the fasteners

Illustration 24 g01137367 Illustration 26 g01137350

9. Loosen the locking screw (10). Install the spacer

Fuel Injector - Remove

Contaminants may cause rapid wear and shortened i02270858

1. Ensure that a cap (1) is installed onto the fuel

3. Remove the exhaust pipe from the turbocharger

7. Remove the banjo bolts (5). Remove the oil supply

1. Remove all of the plastic plugs from all of the ports

9. Position a new joint and the oil drain tube

3. If the studs (15) were previously removed, install

8. Position a new joint (10) and the oil drain tube

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