Tooling Catalogue NAV-2011

Tool
Specialist
Catalogue
Contents
Introduction
Contents
Perkins Service Tools ToolIndex
This revised catalogue forms part of Perkins specialist tooling Service Matrix 04
process. Perkins emphasises to its customers the need to use
properly designed and tested tools in order to carry out service
and maintenance procedures in the most correct, efficient and Engine Tool List
safe manner.
3.152 Series Tools 31
Perkins also recognises that some tools are available more readily 4.236 Series Tools 31
than the more specialised tools developed specifically for procedures 100 Series 36
on Perkins engines. 400 Series 37
800 C–D Series 40
For this reason there is now a defined list of mandatory tools. 900 Series 43
Without these special tools full and proper service of Perkins New 1000 Series 45
engines cannot be performed. 1000 Series 4–6 47
1103 A,B,C,D Series 50
It is Perkins intention that these mandatory tools are always 1104 A,B,C,D Series 53
available from stock. Distributors are expected to have these in their 1104 6D Electronic 56
workshops, for engine types known to be in their territory. Periodical 1204 - 1206 Series 60
checks will occur to maintain the levels to the required standards. 1300 Series 65
2000 - 3000 Series 67
Tools outside of this list may not be in stock at all times but will be 2206 69
supplied within lead-times quoted at the time of order. 2300 - 2500 & 2800 75
4000 Series 82
New Content 90
2 3
2
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
Part No. Description
New
100
400
500
700
800
900
21825491 Piston ring compressor
• • • • • • • • • • •
21825491 Gauge, piston height and
valve head height (use with • • • • • • • • • • • • • • • • • • • • • • • •
21825617)
21825510 Checking gauge, fuel pump

timing
• • • •
21825511 Adaptor / spacer timing
gauge
• •
21825512 Adaptor, timing gauge 4.236
(use with 21825510) • •
21825513 Adaptor, fuel pump timing

gauge • • •
21825515 Adaptor, fuel pump timing -

Bosch (use with 21825510) •
21825528 Injector Analyser

• • • • • • • • •
21825540 Replacer, crankshaft rear
oil seal
• • • • •
21825543 Cylinder liner remover /
replacement tool
•
21825565 Remover, FIP & Cam gear
• • • • •
21825571 Centraliser, timing case cover
(3 cyl)
• • •
21825574 Centraliser, timing cover - 6
cylinder
• • •
21825576 Crankshaft turning adaptor
• • • • • • •
21825577 Replacer, crankshaft front oil
seal - main tool • • • • • • • • •
4
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
21825578 Plate, crankshaft front oil

seal replacement (use with
21825577)
• • • • • • • • • •
21825579 Sleeve, crankshaft front oil

seal (use with 21825577) • • • • • • • • • •

seal • • • • • •
21825581 Crankshaft front oil seal

replacer (use with 21825577) • • • • • • •
21825593 Replacer, camshaft front

oil seal •
21825607 Angle gauge

• • • • • • • • • • • • • •
21825611 Wrench, fuel pump solenoid

• • • • • • •
21825615 Replacer tool for pistons

•
21825617 Dial gauge

• • • • • • • • • • • • • • • • • • • • • • • • • •
21825619 Crankshaft pulley remover

• •
21825620 Front oil seal protector

(403C-11, 402D-05, 403D-
• •
11, 404D-16)
5
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
21825621 Front oil seal protector

(403C-15, 404C-22,
• •
403D-15, 404D-22)
21825623 Valve stem replacer

• •
21825624 Installer, idler gear shaft

(402C-05, 402D-05, • •
403D-07)

(403C-11, 403D-11,
• •
404C-15, 404D-15)

• •
21825639 Driving handle

• • • • • •
21825680 Fuel pump spill pipe

•
21825739 Valve spring compressor

• • • •
21825765 Tool holder, injector sleeve

face cutter / reamer 3000 • • •
Series
21825767 Cutter, injector sleeve face

3000 • • •
21825768 Reamer, injector sleeve face

3000
• • •
21825771 Remover, injector sleeve

3000
• • •
21825776 Tube expander (pattern "C"

type)
• • •
6
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
21825807 Spanner, crankshaft hub

nut 2000
• • •
21825844 Distance piece, cylinder liner

clamp (2000 & 3000)
• • •
21825849 Slide hammer 2000 / 3000

• • •
21825854 Adaptor kit, injector remover

3000 (use with 21825849)
• • •
21825883 Ballizer, injector sleeve 3000

• • •
21825901 Wrench, governor drain

3000 only • • •
21825902 Lapping tool, cylinder liner

(2000 & 3000)
• • •
21825914 Remover, injector 2000

• • •
21825918 Wrench, spark plug sleeve

2000SI • • •
21825920 Wrench, drive coupling

3000 only • • •
21825922 Remover, injector & injector

sleeve 2000 • • •
21825925 Adaptor, valve guide replacer

(use with 21825478) •
21825927 Adaptor, valve spring

compressor (use with • •
21825666)
7
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900

compressor (3.152,
500, 4.236, 900 used • • • •
with 21825666)
21825930 Fuel pump and

camshaft gear • • • • •
remover bolt

compressor (use with • • •
21825666)
21825934 Valve spring

compressor adaptor
(403D-15, 404D-22, • • •
900)
21825936 Centraliser, timing

case (4 cyl) • • •
21825938 Adjustable valve seat

cutters • •
21825941 Adaptors, cylinder

liner remover /
replacer (use with •
21825543)
21825942 Adaptor, cylinder liner

replacer (use with •
21825543)
21825947 Probe, piston

position •
21825951 Socket, lower idler

gear •
8
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
21825952 Plunger timing pin

•
21825953 Installer, front oil seal

•

remover •
21825959 Kit, liner holding

•
21825960 Remover kit, injector

sleeve •
21825963 Installer, rear oil seal

•
21825964 Spanner, for flange

nuts on Bosch fuel
injection pump
21826012 Installer, nozzle

injector sleeve
•

compressor
•
27610021 Replacer tool for idler

gear hub
•
27610022 Replacer, front oil

seal
•
27610025 Adaptor / remover,

idler hub
•
27610026 Adaptor, main tool to

crankshaft nose
•
9
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610029 Exhaust valve guide

adaptor (use with • •
21825478)
27610030 Valve seat and guide

cutter / reamer
• • •
27610031 Coolant pump, oil

seal replacer tool
27610032 Timing pin - Bosch

• • •
27610033 Timing pin - Lucas,

Stanadyne, Delphi •
27610091 Special tap EDI •

27610096 Locking pin for
crankshaft
•
27610122 Fuel pump, drive

gear retaining torx •
screw driver
27610178 Cylinder head spark

plug thread cleaning • • • •
kit
27610179 Flywheel support

studs • • • •
27610209 Tappet chamber oil

plug removal tool •
27610210 Tappet chamber oil

plug fitting tool •
10
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610211 Crankshaft locking

pin
• •
27610212 Camshaft gear

locking pin • •
27610216 Timing case locating

tool • •
27610217 FEOS fitting tool • •

27610218 Piston displacement
tool (1106C)
•
27610225 Balancer locking pin •

27610226 Coolant thermostat
valve assembly tool
• •
27610227 Rocker assembly /

removal - fitting tool
• •
27610230 FEOS removal tool -

twin / triple puller • •
27610234 Inlet & Outlet valve

guide adaptor
• •
27610235 Adaptor for valve

spring compressor
403D-11, 404D-15, • • •
800, 1106D
27610248 Bosch EPVE fuel

injection pump timing
adaptor • •
11
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610251 Compact communications

Adaptor (includes Adaptor,
DL cable RJ45 & PC Cable • • • • • • • • • • • • • • •
USB / AB
27610261 Valve stem seal installer •

27610262 Valve guide driver •
27610263 Valve guide collar •
27610264 Inlet valve seat installer •
27610266 Crankshaft rear end oil seal
installer
•
27610267 Crankshaft pulley socket •

27610268 Crankshaft, front end oil seal
installer
•
27610269 Idler gear shaft puller •

27610272 Compression test gauge
adaptor
•
27610274 Cylinder bore, ridge reamer •

27610275 Crankshaft front bearing
driver group
•
27610281 Lead to connect to 1300EDi

Engine, for use with DIAG
1300 software - Lead •
27610281for use with
12
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610282 1300 Series Edi serial

communication adaptor
(ROW only) Part SS to •
27610283

(Europe only) Part SS to •
27550028
27610284 Installer • • • •
27610286 Crankshaft locking pin
• •
27610287 Crankshaft locking pin

adaptor
27610288 Fuel injector removal tool

- pry bar
• •
27610289 Barring tool gear - used with

housing 27610291
• • • • • • • • • • • • • •
27610291 Engine barring tool housing -

fits in starter motor pocket of
flywheel housing (used with • •
27610289)
27610292 Anchor plate
27610294 Injector pipe nut tool • • •

27610295 Valve spring compressor
head
• •
13
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610296 Torque wrench, electronic

injector connections. A 1/4"
hex to 1/4" square drive
adaptor is required to enable
• • • •
a 1/4" drive socket to be
used)
27610298 Angled feeler gauges • •

27610299 Torx E18 socket for front
pulley fixings
•
27610301 Front oil seal removal tool •

27610302 Fuel pump timing tool
assembly Part SS to •
27610352
27610306 REOS alignment tool •

27610307 Extended Torx driver, for
injector clamp bolt.
•
27610308 Surface reconditioning pad • • • •

27610309 Seal installer • • • •
27610311 Slide hammer- crankshaft
front oil seal removal
• • • •
27610312 Camshaft bearing pilot • • • •

27610313 Taper lock stud • • • •
27610314 Puller plate • • • •
27610315 Alignment bush • • • •
27610316 Backup plate • • • •
14
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610317 Bolt • • • •
27610318 Spacer plate • • • •
27610319 Bearing tool • • • •
27610321 Camshaft alignment tool
27610323 Injector leak off

measurement kit 1104 / 6D
• •
27610325 Fuel pump pressure test "T"

used with 27610326
• •
27610326 Air in fuel sight tube • •

27610327 Installer, idler gear shaft -
403D-15 / 404D-22 all
•
27610331 Dial gauge holder
27610332 Adaptor
27610333 Spring - superseded by

198217970
•
27610337 Hand held code reader

(includes tool, cable &
manual)
27610345 Rear oil seal installation tool

locator
27610346 Rear oil seal installation

tool bolt
27610347 Locator securing bolts

(2 required)
15
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
27610352 Fuel pump timing tool for

1104 / 6D
• •
28170019 3 pin Tyco Ampseal plug (key

1) Oil pressure sensor / rail
pressure sensor
28170036
28170038 70 pin Deutsch

DRCReceptacle key A flange
mount
28170039 4 pin Deutsch DT receptacle

(valve Cvr base) Injector
base cover
28170041 12 pin Deutsch DT plug (key

A) Injector valve cover base
28170044 2 pin Tyco Ampseal plug

(key 1) Coolant temperature
sensor intake manifold
temperature sensor
28170045 3 pin Tyco Ampseal plug (key

2) Intake manifold pressure
sensor (boost)
28170046 2 pin Ampseal plug (key 2)

Wastegate solenoid
28170047 2 pin Ampseal plug (key 3)

Speed / timing sensor
28170048 64 pin 100W plug ECM

engine
28170049 9 pin Deutsch HD receptacle

- Diagnostic connector
16
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
28170051 2 pin Deutsch DT plug /

smaller rear seal, speed /
timing sensor
28170052 3 pin Deutsch DT

receptacle / smaller rear
seal - Atmospheric pressure
sensor
28170053 12 pin Deutsch receptacle

flange mount - injector valve
cover base
28170054 70 pin Deutsch DRC plug

key A - OEM machine
interface connector Part SS
to 2800A009
28170084 Deutsch socket - used with

1100 C / D
28170085 Roll formed socket for 100W

connector OEM & Engine
ECM connector
28170086 Lock connector TPA for

100W connector - OEM
& Engine ECM connector
(2 required) Part SS to
28170034
28170086 Lock connector TPA for

100W connector - OEM
& Engine ECM connector
(2 required) Part SS to
28170034
28170087 End bell Delphi 100W

connector - OEM & Engine
ECM connector Part SS to
28170035
17
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
28170088 Sealing plug for 28170048 OEM

& engine ECM connector Part SS
to 28170036
2874A211 CANtrak 2200 with GEM

S/W (replaces 2800A003
2880A016 LCG2 communication

adaptor
• • • • • •
2900A011 Seal plug (fills unused pin

locations) used with 2800A010 or
2800A012 throttle assemblies
2900A012 Clip arrow head - harness

clip
• •
2900A015 Clip - Fir tree harness clip

• •
2900A036 Power up harness • •

2900A037 Bypass harness • •
2900A038 Power up harness • •
2900A504 70 pin MIC breakout
harness
• • •
838/22 Timing calibration pick up

probe - 4016TRS
• • • •
CH10047 "O" ring - part of CH11147

oil sampling kit
• • •
CH10133 "O" ring - part of CH11147

oil sampling kit
• • •
CH10820 Adaptor - part of CH11147

oil sampling kit
• • •
CH10821 Dust cap - part of CH11147

oil sampling kit
• • •
18
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
CH10822 Sampling valve - part of

CH11147 oil sampling kit
• • •
CH11148 Engine turning tool - part of

CH11150
• • •
CH11149 Setting gauge, fuel injector

- part of CH11150
• • •
CH11150 Essential maintenance

tool kit
• • •
CH11155 Crimp tool for harness

repair kits
• • • • • •
CH11169 Terminal insertion /

extraction tool
• • •
CH12090 Piston ring compressor -

2800 Series 18 litre
• • •
CH12571 Cylinder clamp hard washer

• • •
CVT0001 Valve guide driver

• • •
CVT0002 Valve guide collar

• • •
CVT0003 Valve spring compressor

• • •
CVT0004 Camshaft pilot

• • •
CVT0005 Camshaft pilot

• • •
CVT0006 Receiving sleeve

• • •
CVT0007 Puller plate

• • •
CVT0008 Bearing pilot

• • •
19
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
CVT0009 Back up plate

• • •
CVT0010 Taperlock stud - cam

bearing installation
• • •
CVT0011 Extension - short

• • •
CVT0012 Extension - long

• • •
CVT0013 Crank gear sleeve

• • •
CVT0014 Crank gear gauge

• • •
CVT0015 Timing pin adaptor

• • •
CVT0016 Piston ring compressor

• • •
CVT0018 Front wear sleeve installer

• • •
CVT0019
• • •
GE50000 Installer, cylinder liner

• • •
GE50001 Remover, cylinder liner

• • •
GE50002 Height tool, cylinder liner

• • •
GE50003 Piston ring compressor

• • •
20
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
GE50005 Clamp bolt, cylinder liner

(26 required)
• • •
GE50006 Washer (26 required)

• • •
GE50007 Fibre washer (26 required)

• • •
GE50008 Locator, crankshaft seal

• • •
GE50009 Bolt, crankshaft seal

installer (use with GE50008)
• • •
GE50010 Distorter, protection ring

(use with GE50008)
• • •
GE50011 Distorter tool (use with

GE50008)
• • •
GE50012 Installer, front crankshaft

seal (use with GE500008)
• • •
GE50013 Installer, rear crankshaft

seal (use with GE50008)
• • •
GE50014 Nut (use with GE50008)

• • •
GE50015 Pilot, camshaft guide

• • •
GE50016 Alignment sleeve, camshaft

guide
• • •
GE50017 Guide, camshaft

• • •
GE50018 Guide, camshaft

• • •
21
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
GE50019 Guide stud, camshaft gear

• • •
GE50020 Impact socket

• • •
GE50021 Remover / installer, injector

sleeve
• • •
GE50022 Brush, large bore

• • •
GE50023 Brush, small tapered

• • •
GE50024 Brush, small bore

• • •
GE50025 Lifting hook, camshaft

• • •
GE50026 Compressor, valve spring

• • •
GE50027 Installer, valve guide seal

• • •
GE50028 Vacuum pump

• • •
GE50029 Vacuum pump bottle SS to

GE50046
• • •
GE50030 Vacuum pump tube

• • •
GE50031 Pressurising pump, coolant

system
• • •
GE50032 Thermometer, coolant

temperature
• • •
22
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
GE50033 Pressure gauge

• • •
GE50036 Service bypass harness

• • •
GE50037 70 pin breakout harness

(replaces 2900A025)
• • •
GE50038 Engine timing probe

• • •
GE50039 Timing probe adaptor

• • •
GE50040 Deutsch "DT" timing probe

cable
• • •
GE50041 3 pin DT breakout harness

(replaces 2900A024)
supercedes to Part • • •
No.CVT0019.
GE50042 Signal reading probe

• • •
GE50043 Remover / installer, Valve

guide
• •
GE50044 Sleeve, valve guide

• •
GE50045 Piston ring compressors

• •
GE50046 Vacuum pump bottle

• • • •
KRP1752 Oil sample kit

• • • •
23
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
SE254 Engine turning tool

• • • •
T400005 Spark plug bore, wire brush

•
T400006 Special 17mm socket

•
T400011 Engine barring tool - fixes

to crankshaft pulley
•
T400014 Engine timing pin, locks

crankshaft at TDC
•
T400015 Fuel pump locking pin,

locks pump for removal / •
refitting with engine at TDC
T400016 Bayonet front end oil seal

fitting / removal tool - all
1200 Series engines with •
steel front covers
T400017 Timing case cover

alignment tool for 6 cylinder
1200 Series products with •
steel timing case cover.
T400018 Centralising dolly for cast

iron timing case cover, 6
cylinder 1200 Series option •
T400019 Exhaust manifold alignment

pins - 2 required to support
manifold on 6 cylinder 1200 •
Series product.
24
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
T400020 Exhaust manifold alignment

pins - 2 required to support
manifold and joints on •
6 cylinder 1200 Series
product.
T400021 Twin turbocharger

alignment tool •
T400022 Timing case cover

alignment tool for 4 cylinder •
1200 Series product
T400023 Centralising dolly for cast

iron timing case cover, 4 •
cylinder 1200 Series option
T400025 Attenuator tool, RF sensor

lead connector
•
T400026 Spark indicator for testing

CEM spark plug
•
T6253/139 Piston ring compressing

tool (use with 21825577)
• • • •
T6253/140 Rear oil seal insertion kit

(use with 21825639)
• • • •
T6253/141 Front oil seal insertion kit

(4006) use with 21825577
• • • •
T6253/141A Front oil seal insertion kit

(4008)
• • • •
T6253/144 Timing disc

• • • •
25
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
T6253/146 Injector clamp and fuel feed

adaptor
• • • •
T6253/146B Set of spare "O" rings
T6253/147 Injector compressor kit

• • • •
T6253/149 1/2" Core plug inserter

• • • •
T6253/151 Cam bearing removal /

refitting tool
• • • •
T6253/152 Liner extractor

• • • •
T6253/154 Cylinder head lifting tool

• • • •
T6253/156 Injector bush coning tool

(use with 21825589)
• • • •
T6253/157 Support studs, flywheel and

damper
• • • •
T6253/172 Fuel setting tool (early

engines)
• • • •
T6253/177 Fuel setting tool (later

engines)
• • • •
T6253/200 Liner clamp kit

• • • •
28170091 4 pin Deutsch DTP plug /

smaller rear seal - VLPM
connector
26
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
28710476 Hard washer
29990021 Bolt
198217970 Supercedes from 27610333

Spring
Oil sampling tool kit - part

of CH11150
2755A151 Coolant temperature

gauges 12 volt illumination
(5V) PWM
2755A152 Coolant temperature

gauges 24 volt illumination
(5V) PWM
2755B151 Oil pressure gauge 12 volt

illumination (5V) PWM
2755B152 Oil pressure gauge 24 volt

illumination (5V) PWM
2758A551 Tacho 12 Volt illumination,

pulse driven
2758A552 Tacho 24 Volt illumination,

pulse driven
27610164 * TIPSS communications

adaptor tool kit. (includes
communications adaptor,
short unicable, serial cable,
• • •
case & operators manual)
SS to 27610251
27610187* Hand held code reader

manual) SS to 27610337
27
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
2874A211 CANtrak 2200 with GEM

S/W (replaces 2800A003
27610164 * TIPSS communications

adaptor tool kit. (includes
• • •
SS to 27610251
27610187* Hand held code reader

manual) SS to 27610337
T6253/202 Injector nozzle cleaning

tools
• • • •
T6253/208 Nozzle test master / injector

tester
• • • •
T6253/209 Crankshaft pulley extractor • • • •

T6253/212 Piston crown handle • • • •
T6253/214 TV damper removal kit • • • •
T6253/236 Lifting eye • • • •
T6253/238 Circlip pliers - internal • • • •
T6253/256 Piston ring pliers • • • •
T6253/295 Piston removal tool • • • •
T6253/307 Fuel injector extractor • • • •
T6253/353 Fuel injector setting tool -
large spring injectors
• • • •
28
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
T6253/356 Revised injector test

adaptor 14.00mm plunger
• • • •
T6254/146A Injector clamp and fuel feed

adaptor SS to T6253/146
T85001/33 Gear spacing tool • • • •

T85001/34 Crankshaft lifting bracket • • • •
T85002/14B Injector bush depth gauge • • • •
T85002/4 Valve seat inserting guide • • • •
T85002/58 Injector bush expanding
tool (upper)
• • • •
T85316/1 Front oil insertion kit • • • •

T9142/8 Cup plug mandrel • • • •
U5MK0662 Wiring harness repair kit -
SS to U5MK8194
• • • • •
U5MK1092 Spoon kit - Red & black

(contains 7X-1708 & 7X- • • • • •
1709)
U5MK1110 Harness repair kit –

Ampseal. Contains pins,
wires, connector seals & • • • • • • • • • • • • • •
connector bodies.
U5MK1123 LCG1 communication

adaptor
• • • • • •
U5MK1124 Fuel system cleanliness kit

(plugs / caps)
29
Contents
Service Matrix
3.152
4.236
1000
1000
1103
1104
1106
1200
1300
2006
2206
2306
2500
2806
3008
3012
4006
4008
4012
4016
New
100
400
500
700
800
900
U5MK1130 ECG Electronic control

governor communication kit • •
U5MK8194 Harness repair kit –

Deutsch. Contains pins,
wires, connector seals &
connector bodies. Also • • •
used with 1104C/6C,
1104/6D, 2300 / 2800
Series products.
VP12712 Lift bracket, cylinder • •

Y03/00031 DCG Digital control
governor communications • • • •
kit
30
Contents
3.152 Series
Cylinder Head
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and All products R

valve head height (use with
21825617)
FIE
21825611 Wrench, fuel pump solenoid Engines fitted R

with mechanical
rotary fuel
injection pumps
Timing
21825510 Checking gauge, fuel pump 3.152 / 4.236 M

timing
21825930 Fuel pump and camshaft gear 3.152 / 4.236 R

remover bolt
Crankshaft
21825540 Replacer, crankshaft rear oil 3.152 / 4.236 R

seal
21825571 Centraliser, timing case cover 3.152 R

(3 cyl)
Note
31 M - Mandatory R - Recommended Contents
Contents
3.152 Series
Crankshaft continued
21825577 Replacer, crankshaft front oil 3.152 / 4.236 / R

900 /
seal - main tool 1000 Series,
1100 Series,
1200 Series
21825578 Plate, crankshaft rear oil seal 3.152 / 4.236 / R

900 /
(use with 21825577) 1000 Series,
1100 Series,
1200 Series
21825580 Plate, crankshaft front oil seal 3.152 / 4.236 R
21825579 Sleeve, crankshaft front oil seal 3.152 / 4.236 R

(use with 21825577) / 1000 Series
General
21825617 Dial gauge All products R
Electrical
2880A016 LCG2 communication adaptor 3.152 / 4.236 M

/ 1000 Series
U5MK1123 LCG1 communication adaptor 3.152 / 4.236 M

/ 1000 Series
Note
Contents
4.236 Series
Cylinder Head

21825617)
21825607 Angle gauge All products R
FIE
21825611 Wrench, fuel pump solenoid Engines R

fitted with
mechanical
rotary fuel
injection
pumps
Timing
21825510 Checking gauge, fuel 3.152 / 4.236 M

injection pump timing
21825512 Adaptor, timing gauge 3.152 / 4.236 M

4.236 (use with 21825510)
21825513 21825513 adaptor, fuel 3.152 / 4.236 M

pump timing gauge
21825930 Fuel pump and camshaft 3.152 / 4.236 R

gear remover bolt
Note
32
Contents
4.236 Series
Crankshaft
21825540 Replacer, crankshaft rear 3.152 / 4.236 M

oil seal
21825576 Crankshaft turning adaptor 3.152 / 4.236 R
21825577 Replacer, crankshaft front 3.152 / 4.236 / R

900 /
oil seal - main tool 1000 Series,
1100 Series,
1200 Series
21825578 Plate, crankshaft rear oil 3.152 / 4.236 / R

900 /
seal (use with 21825577) 1000 Series,
1100 Series,
1200 Series
21825579 Sleeve, crankshaft rear oil 3.152 / 4.236 / R

900 /
seal (use with 21825577) 1000 Series,
1100 Series,
1200 Series
21825580 Plate, crankshaft front oil 3.152 / 4.236 R

seal
21825581 Crankshaft front oil seal 3.152 / 4.236 R

replacer (use with 21825577)
General
21825565 Remover, FIP & Cam gear 3.152 / 4.236 R
21825936 Centraliser, timing case 4.236 M

(4 cyl)
Note
Contents
4.236 Series
Electrical
2880A016 LCG2 communication 3.152 / 4.236 M

adaptor / 1000 Series
U5MK1123 LCG1 communication 3.152 / 4.236 M

Note
34
Contents
100 Series
Cylinder Block
21825624 Installer, idler gear shaft 402C-05, M

(402C-05, 402D-05, 403D-07) 402D-05,
403D-07

(403C-11, 403D-11, 404C-15, 403D-11,
404D-15) 404C-15,
404D-15
21825626 Installer, idler gear shaft 404C-22 M
General

21825617)
Note
Contents
400 Series
Cylinder Head
21825623 Valve stem replacer 400 Series R
21825739 Valve spring compressor 400 Series R
21825934 Valve spring compressor 403D-15, R

adaptor (403D-15, 404D-22
404D-22)
27610296 Torque wrench, crank 400 Series, R

breather 1100
electronic,
1200 Series
27610235 Adaptor for valve spring 403D-11, R

compressor 403D-11, 404D-15,
404D-15, 1106D 1106D
FIE
27610294 Injector pipe nut tool 400 Series, R

1100 / 1200
Series
21825680 Fuel pump spill pipe 400 Series R
Crankshaft
27610311 Slide hammer - crankshaft 400 Series R

Note
36
Contents
400 Series
27610275 Crankshaft front bearing 400 Series R

driver group
21825619 Crankshaft pulley remover 400 Series R
21825620 Front oil seal protector (403C-11, R

(403C-11, 402D-05, 403D- 402D-05,
403D-11,
11, 404D-16)
404D-16)
21825621 Front oil seal protector (403C-15, R

(403C-15, 404C-22, 403D-15, 404C-22,
404D-22) 403D-15,
404D-22)
Cylinder Block
27610274 Cylinder bore, ridge reamer 400 Series R
21825491 Piston ring compressor All products R

(403C-11, 403D-11, 404C- 403D-11,
404C-15,
15, 404D-15)
404D-15
21825626 Installer, idler gear shaft M
27610327 Installer, idler gear shaft - 404C-22, M

403D-15 / 404D-22 all 404D-22
Note
Contents
400 Series
General

21825617)
27610331 Dial gauge holder 400 Series M
27610332 Adaptor 400 Series R
27610333 Spring - superseded by 400C R

198217970
Electrical
U5MK1130 ECG Electronic control All M

governor communication kit electronically
controlled 400
Series
Note
38
Contents
800 c-d Series
Cylinder Head
27610261 Valve stem seal installer
27610262 Valve guide driver
21825938 Adjustable valve seat

cutters
27610264 Inlet valve seat installer
27610263 Valve guide collar
FIE
27610294 Injector pipe nut tool
27610272 Compression test gauge

adaptor
27610296 Glow plug nut, torque

wrench
Note
Contents
800 c-d Series
Crankshaft
27610267 Crankshaft pulley socket
27610311 Slide hammer - crankshaft

27610268 Crankshaft, front end oil

seal installer

locator
27610347 Locator securing bolts

(2 required)
27610266 Crankshaft rear end oil seal

installer

bolt
28710476 Hard washer
Note
40
Contents
800 c-d Series
General
27610274 Cylinder bore, ridge reamer
21825491 Piston ring compressor
27610275 Crankshaft front bearing

driver group
27610269 Idler gear shaft puller
21825617 Dial gauge
Note
Contents
900 Series
Cylinder Head

21825617)
21825607 Angle gauge
FIE
21825510 Checking gauge, fuel pump

timing
21825611 Wrench, fuel pump solenoid
21825513 Adaptor, fuel pump timing

gauge
21825565 Remover, FIP & Cam gear
Timing
27610096 Crankshaft locking pin, fits

through the backplate and
engages with a drilling in the
flywheel
Note
42
Contents
900 Series
Crankshaft
21825576 Crankshaft turning adaptor
21825577 Replacer, crankshaft front

oil seal - main tool

seal (use with 21825577)
21825540 Replacer, crankshaft rear

oil seal
21825579 Sleeve, crankshaft rear oil

General
21825571 Centraliser, timing case

cover (3 cyl)
21825617 Dial gauge
Note
Contents
New 1000 Series
Cylinder Head

21825617)
FIE
27610032 Timing pin - Bosch New 1000

M
Series
27610033 Timing pin - Lucas, New 1000 M

Stanadyne, Delphi Series
27610122 Fuel pump, drive gear New 1000 M

retaining torx screw driver Series

fitted with
mechanical
rotary fuel
injection
pumps
Note
44
Contents
New 1000 Series
Crankshaft
T400011 Engine barring tool - fixes New 1000 R

to crankshaft pulley Series /
1100 Series /
1200 Series
21825577 Replacer, crankshaft front 3.152 / 4.236 R

oil seal - main tool / 900 /
1000 Series,
1100 Series,
1200 Series
21825578 Plate, cranklshaft rear oil 3.152 / 4.236 R

seal (use with 21825577) / 900 /
1000 Series,
1100 Series,
1200 Series

seal / 1000 Series
21825579 Sleeve, crankshaft rear oil 3.152 / 4.236 R

seal (use with 21825577) / 1000 Series

replacer (use with 21825577) / 1000 Series
Electrical
2880A016 LCG2 communication 3.152 / 4.236 M

U5MK1123 LCG1 communication 3.152 / 4.236 M

Note
Contents
1000 Series 4 – 6
Cylinder Head
21825947 Probe, piston position 1000 Series

M
FIE

fitted with
mechanical
rotary fuel
injection
pumps
21825515 Adaptor, fuel pump timing - Engines with R

Bosch (use with 21825510) Bosch FIE
21825510 Checking gauge, fuel pump 3.152 / 4.236 M

timing / 1000 Series
21825513 Adaptor, fuel pump timing 3.152 / 4.236 M

gauge / 1000 Series
21825565 Remover, FIP & Cam gear 3.152 / 4.236 R
21825512 Adaptor, timing gauge 3.152 / 4.236 M

4.236 (use with 21825510) / 1000 Series
21825930 Fuel pump and camshaft 3.152 / 4.236 R

gear remover bolt
Note
46
Contents
1000 Series 4 – 6
Crankshaft
T400011 Engine barring tool - fixes 1000 Series / R

to crankshaft pulley 1100 Series /
1200 Series
21825577 Replacer, crankshaft front 3.152 / 4.236 R

oil seal - main tool / 1000 Series
/ 1100 Series
/ 1200 Series
21825578 Plate, crankshaft rear oil 3.152 / 4.236 R

/ 1100 Series
/ 1200 Series

seal / 1000 Series
21825579 Sleeve, crankshaft rear oil 3.152 / 4.236 R


replacer (use with 21825577) / 1000 Series
21825540 Replacer, crankshaft rear 3.152 / 4.236 R

oil seal / 1000 Series
Note
Contents
1000 Series 4 – 6
General
21825936 Centraliser, timing case 1004 R

(4 cyl)
21825574 Centraliser, timing cover - 1006 R

6 cylinder
21825942 Adaptor, cylinder liner 4.236 / R

remover / replacer (use with 1000 Series
21825543)
21825941 Adaptors, cylinder liner 4.236 / R

remover / replacer (use with 1000 Series
21825543)

21825617)
21825639 Driving handle R
Note
48
Contents
1103 a b c d Series
Cylinder Head
27610226 Coolant thermostat valve 1103 / 4C R

assembly tool
27610227 Rocker assembly / removal 1100C M

- fitting tool
21825496 Gauge, piston height and valve All products R

head height (use with 21825617)
FIE
27610248 Bosch EPVE fuel injection 1104C M

pump timing adaptor
Timing
27610211 Crankshaft locking pin 1103 / 1104C M
27610212 Camshaft gear locking pin 1103 / 4C M
Note
Contents
1103 a b c d Series
Crankshaft
27610230 FEOS removal tool - twin / 1103C R

triple puller
21825577 Replacer, crankshaft front All products R

21825578 Plate, crankshaft rear oil All products R

27610217 FEOS fitting tool 1104C / D R
21825580 Plate, crankshaft front oil 1103 / 4 C&D R

seal
General
27610216 Timing case locating tool 1100 Series
T400011 Engine barring tool - fixes 1100 / R

to crankshaft pulley 1200 Series
engines
Note
50
Contents
1103 a b c d Series
Electrical
2880A016 LCG2 communication Engines M

adaptor fitted with
Woodward
governors
2900A504 70 pin MIC breakout R

harness
U5MK8194 Harness repair kit – 1104C / R

Deutsch. Contains pins, 6C, 1104 /
wires, connector seals & 6D, 2300 /
2800 Series
connector bodies. Also
products.
used with 1104C/ 6C, 1104/
6D, 2300 / 2800 Series
products
Note
Contents
1104 a b c d Series
Cylinder Head
27610226 Coolant thermostat valve 1103 / 4C R

assembly tool
27610227 Rocker assembly / removal 1103 / 4C R

- fitting tool

21825617)
FIE
27610032 Timing pin - Bosch 1104C R

electronic
Timing
27610211 Crankshaft locking pin 1103 / 4C&D M
27610212 Camshaft gear locking pin 1103 / 4C & M

1200 Series
27610225 Balancer locking pin 1104C / M

1204E
Note
52
Contents
1104 a b c d Series
Crankshaft
T400011 Engine barring tool - fixes 1100 / 1200 R

to crankshaft pulley Series
27610230 FEOS removal tool - twin / 1103 / 4/ 6C R

triple puller

21825578 Plate, crankshaft rear oil All products R

27610217 FEOS fitting tool 1103 / 4C R
21825580 Plate, crankshaft front oil 1103 / 4C R

seal
General
27610216 Timing case locating tool 1103 / 4/ 6C R
Note
Contents
1104 a b c d Series
Electrical
U5MK8194 Harness repair kit – 1104 / 6C, R

Deutsch. Contains pins, 1104 / 6D,
wires, connector seals & 2300 & 2800
used with 1104C/ 6C, 1104/
6D, 2300 / 2800 Series
products.
Ampseal. Contains pins, 1104 / 6D,
connector bodies.
CH11155 Crimp tool for harness 1104 / 6C, R

repair kits 1104 / 6D,
2300 & 2800
2880A016 LCG2 communication 1000 Series, M

adaptor 1100 Series
27610251 Compact communications All electroni- M

adaptor (includes adaptor, cally (ecm)
controlled
DL cable RJ45 & PC Cable
products
USB / AB
27610164 * TIPSS communications All electroni-

adaptor tool kit. (includes cally (ecm)
controlled
products
SS to 27610251
U5MK0668
Note
54
Contents
1104 – 6D electronic
Cylinder Head
21825739 Valve spring compressor 1104D / R

1106D /
1200 Series
27610235 Adaptor for valve spring 1104D / R

compressor 403D-11, 1106D /
404D-15, 1106D 1200 Series
27610295 Valve spring compressor 1104D / R

head 1106D /
1200 Series
FIE
27610352 Fuel pump timing tool for 1104D / M

1104 / 6D 1106D
electronic
engines
27610294 Injector pipe nut tool 1104 all / M

1106 C&D /
1200 Series
27610296 Torque wrench, electronic 400 Series M

injector connections. ( A / 1104D
/ 1106D
1/4" hex to 1/4" square
electronic /
drive adaptor is required to 1200 Series
enable a 1/4" drive socket
to be used)
27610323 Injector leak off 1104D / M

measurement kit 1104 / 6D 1106D elec-
tronic engines
27610326 Air in fuel sight tube 1104D R

/ 1106D
electronic
engines
Note
Contents
FIE continued
27610325 Fuel pump pressure test "T" 1104D / R

used with 27610326 1106D
electronic
engines
27610307 Extended Torx driver, for 1104D / R

injector clamp bolt. 1106D elec-
tronic engines
& 1200 Series
U5MK1124 Fuel system cleanliness kit 1100D all M

(plugs / Caps)
27610288 Fuel injector removal tool - 1104D / M

pry bar 1106D /
1200 Series
Timing
27610286 Crankshaft locking pin 1104D / M

1106D
27610212 Camshaft gear locking pin 1104A / B / M

C/D&
1200 Series
27610225 Balancer locking pin 1104C / D M

&1204E
Note
56
Contents
Crankshaft

27610284 Installer 1000 Series R

/ new 1000
Series /
1100 Series /
1200 Series
21825578 Plate, cranklshaft oil seal 1000 Series R

(use with 21825577) / new
1000 Series /
1100 Series /
1200 Series
27610292 Anchor plate 1106D R
27610217 FEOS fitting tool 1104C & D R
27610301 Front oil seal removal tool 1106D R
T400011 Engine barring tool - fixes 100D & R

General
27610216 Timing case locating tool 1100C & D R
27610289 Barring tool gear - used All products R

with housing 27610291
27610291 Engine barring tool housing - All products R

fits in starter motor pocket of
flywheel housing (used with
27610289)
Note
Contents
General continued
27610298 Feeler gauges 1106D R
27610299 Torx E18 socket for front 1100 Series / M

pulley fixings 1200 Series

21825617)
Electrical
U5MK8194 Harness repair kit – Deutsch. 1100 Series / R

Contains pins, wires, 2300 /
connector seals & connector 2800 Series
bodies. Also used with
1104C/ 6C, 1104/ 6D, 2300 /
2800 Series products
U5MK1110 Harness repair kit – Ampseal. 1100 Series / R

Contains pins, wires, connec- 2300 /
tor seals & connector bodies 2800 Series
CH11155 Crimp tool for harness repair 1100 Series / R

kits 2300 / 2800
Series
27610251 Compact communications All ECM M

adaptor (includes adaptor, controlled
DL cable RJ45 & PC Cable electronic
USB / AB products
27610164 * TIPSS communications All ECM M

adaptor tool kit. (includes controlled
communications adaptor, electronic
short unicable, serial cable, products
case & operators manual) SS
to 27610251
Note
58
Contents
1204 – 1206 Series
Cylinder Head
T400027 Rocker arm spacer tool - 6 1204 / 6E R

required on 6 litre products &
4 required on 4 litre products
21825739 Valve spring compressor 1104 / 6D, R

1200 Series
27610235 Adaptor for valve spring 1104 / 6D, R

compressor 403D-11, 1200 Series
404D-15, 1106D
27610295 Valve spring compressor 1104 / 6D, R

head 1200 Series
FIE
T400015 Fuel pump locking pin, 1200 Series M

locks pump for removal /
refitting with engine at TDC
27610294 Injector pipe nut tool 1100 Series, M
1200 Series
27610296 Torque wrench, electronic 400 Series, M

injector connections. ( A 1100D,
1/4" hex to 1/4" square drive 1200 Series
adaptor is required to enable
a 1/4" drive socket to be
used)
For access to fuel line 1200 Series M

connectors - Snapon
U4668898ANM
27610288 Fuel injector removal tool - 1100D M
pry bar electronic /
1200 Series
Note
Contents
1204 – 1206 Series
Timing
T400014 Engine timing pin, locks 1106D M

crankshaft at TDC 1200 Series
27610225 Balancer locking pin 1104C / D, M

1204E
Crankshaft
T400011 Engine barring tool - fixes 1100D / M

T400016 Bayonet front end oil seal 1200 Series M

fitting / removal tool - all 1200
Series engines with steel
front covers
T400017 Timing case cover alignment 1206E / 7.1 M

tool for 6 cylinder 1200 Series
products with steel timing
case cover
T400018 Centralising dolly for cast iron 1206E / 7.1 R

timing case cover, 6 cylinder
1200 Series option
T400022 Timing case cover 1204E M

1200 Series product
T400023 Centralising dolly for cast 1204E R


Note
60
Contents
1204 – 1206 Series
27610284 Installer - used with 1100 / R

21825577 1200 Series
21825578 Plate, cranklshaft oil seal All products R

(use with 21825577)
27610217 FEOS fitting tool 1106D short R

nose crank,
1206 Series
General
27610289 Barring tool gear - used All products R

with housing 27610291
27610291 Engine barring tool housing All products R

- fits in starter motor pocket
of flywheel housing (used
with 27610289)
27610299 Torx E18 socket for front 1106D / M
pulley fixings 1200 Series

21825617)
T400021 Twin turbocharger 1206E R
alignment tool
Twin turbocharger 1204E R

alignment tool
T400028 Turbocharger counter 1206E R

balance weight
Note
Contents
1204 – 1206 Series
General continued
Electrical

Deutsch. Contains pins, 1104 / 6D,
used with 1104C/6C,
1104/6D, 2300 / 2800
Series products
CH11155 Crimp tool for harness 1104 / 6C, R
repair kits 1104 / 6D,
2300 & 2800
27610251 Compact communications All electroni- M

adaptor (includes adaptor, cally
controlled
products
USB / AB
27610164 * TIPSS communications All electroni- R
adaptor tool kit. (includes cally control-
communications adaptor, led products
SS to 27610251
CA3 Series 3 communications All ECM M

adaptor controlled
products
Note
62
Contents
1204 – 1206 Series
After Treatment
T400005 Spark plug bore, wire brush 1200 Series R
T400026 Spark indicator (Ground 1200 Series R

lead also required)
T400031 Spark indicator grounding 1200 Series R

lead
T400025 RF sensor lead connector 1200 Series R
T400006 Socket - special 17.00mm 1200 Series R
Note
Contents
1300 Series
FIE
21825960 Remover kit, injector sleeve
21826012 Installer, nozzle injector

sleeve
Timing
21825951 Socket, lower idler gear
21825952 Plunger timing pin
Crankshaft
21825953 Installer, front oil seal
21825963 Installer, rear oil seal
21825965 Remover, crankshaft pulley
Note
64
Contents
1300 Series
General

21825617)

remover
21825959 Kit, liner holding
Electrical
27610281 Lead to connect to 1300EDi

Engine, for use with DIAG
1300 software - Lead
27610281
27610251 Compact communications
adaptor (includes adaptor,
USB / AB
(ROW only) Part SS to
27610283
(Europe only) Part SS to
27550028
Note
Contents
2000 – 3000 Series
Cylinder Head

compressor 3000

compressor 3000
FIE
21825765 Tool holder, injector sleeve

face cutter / reamer 3000
Series
21825767 Cutter, injector sleeve face

3000
21825768 Reamer, injector sleeve face

3000
21825771 Remover, injector sleeve

3000
21825776 Tube expander (pattern "C"

type)
21825854 Adaptor kit, injector

remover 3000 (use with
21825849)
21825883 Ballizer, injector sleeve

3000
Note
66
Contents
2000 – 3000 Series
FIE continued
21825901 Wrench, governor drain

3000 only
21825914 Remover, injector 2000
21825918 Wrench, spark plug sleeve

2000SI
21825920 Wrench, drive coupling

3000 only
21825922 Remover, injector & injector

sleeve 2000
Crankshaft
21825807 Spanner, crankshaft hub

nut - 2000
Note
Contents
2206
Cylinder Head
27610288 Fuel injector removal tool - 1106D, 2206, R

pry bar 1200 Series
CVT0001 Valve guide driver 2206 M
CVT0002 Valve guide collar 2206 M
CVT0003 Valve spring compressor 2206 M
27610296 Torque wrench, electronic 1106D, R

injector connections. ( A 1200 Series,
1/4" hex to 1/4" square 2206
drive adaptor is required to
enable a 1/4" drive socket
to be used)
21825607 Angle gauge All products M
27610309 Water temperature regulator 2206 M

- seal installer
Note
68
Contents
2206
FIE
GE50021 Remover / installer, injector 2206 M

sleeve
GE50028 Vacuum pump 2206 M
GE50046 Vacuum pump bottle 2206 M
GE50030 Vacuum pump tube 2206 M
GE50022 Brush, large bore 2206 M
GE50023 Brush, small tapered 2206 M
GE50024 Brush, small bore 2206 M
Note
Contents
2206
Timing
CVT0004 Camshaft pilot 2206 M
CVT0005 Camshaft pilot 2206 M
CVT0006 Receiving sleeve 2206 M
CVT0007 Puller plate 2206 M
CVT0008 Bearing pilot 2206 M
CVT0009 Back up plate 2206 M
CVT0010 Taperlock stud - cam 2206 M

bearing installation
CVT0011 Extension - short 2206 M
CVT0012 Extension - long 2206 M
Note
70
Contents
2206
Crankshaft
CVT0017 Rear wear sleeve installer 2206 M
CVT0018 Front wear sleeve installer 2206 M
27610319 Bearing tool 2206 M
21825617 Dial gauge All products M
CVT0013 Crank gear sleeve 2206 M
CVT0014 Crank gear gauge 2206 M
CVT0015 Timing pin adaptor 2206 M
27610286 Crankshaft locking pin 1104/6D M
Note
Contents
2206
Electrical
CH11169 Terminal insertion / 2206 M

extraction tool
CH11155 Crimp tool for harness 1100C / D, M

2300, 2500
repair kits 2800, 1200
Series
GE50036 Service bypass harness 2206 M
GE50037 70 pin (AMP) breakout 2206 M

harness (replaces
2900A025)
GE50038 Engine timing transducer 2206 M
GE50039 Engine timing transducer 2206 M

adaptor
GE50040 Deutsch "DT" timing probe 2206 M

cable
GE50042 Signal reading probe 2206 M
Note
72
Contents
2206
General
GE50000 Installer, cylinder liner 2206 M
GE50001 Remover, cylinder liner 2206 M
GE50002 Height tool, cylinder liner 2206 M
CVT0016 Piston ring compressor 2206 M
29990021 Cylinder bolt clamp 2206 M
CH12571 Cylinder clamp hard washer 2206 M
GE50006 Washer (26 required) 2206 M
GE50007 Fibre washer (26 required) 2206 M
CH11148 Engine turning tool 2206 R
CH11147 Oil sampling tool kit, 2206 R

contains: adaptor CH10820,
sampling valve CH10822,
dust cap CH10821, O-ring
CH10133, O-ring CH10047
KPR1572 Oil sample kit, comprising 2206 M

of: sampling adaptor
33871121, sampling bottle
CH11144, self adhesive
labels 21820176
CH11150 Essential maintenance tool 2206 R

kit, comprising of: engine
turning tool CH11148,
injector setting tool
CH11149, oil sampling tool
CH11147, oil sampling kit
KRP1572, toolbox CH11305
Note
Contents
2300 –2500 & 2800
Cylinder Head
GE50020 Impact socket 2300, 2500, M

2800
GE50021 Remover / installer, injector 2300, 2500, M

sleeve 2800
GE50022 Brush, large bore 2300, 2500, M

2800
GE50023 Brush, small tapered 2300, 2500, M

2800
GE50024 Brush, small bore 2300, 2500, M

2800
GE50026 Compressor, valve spring 2300, 2500, M

2800
GE50027 Installer, valve guide seal 2300, 2500, R

2800
GE50043 Remover / installer, valve 2300, 2500, R

guide 2800
GE50044 Sleeve, valve guide 2300, 2500, R

2800
Note
74
Contents
2300 –2500 & 2800
FIE
CH11149 Setting gauge, fuel injector 2300, 2500, M

- part of CH11150 2800
GE50028 Vacuum pump 2300, 2500, M

2800
GE50029 Vacuum pump bottle 2300, 2500, M

SS to GE50046 2800
GE50030 Vacuum pump tube 2300, 2500, M

2800
Timing
GE50015 Pilot, camshaft guide 2300, 2500, M

2800
GE50016 Alignment sleeve, camshaft 2300, 2500, R

guide 2800
GE50017 Guide, camshaft 2300, 2500, M

2800
GE50018 Guide, camshaft 2300, 2500, R

2800
GE50019 Guide stud, camshaft gear 2300, 2500, R

2800
GE50025 Lifting hook, camshaft 2300, 2500, R

2800
Note
Contents
2300 –2500 & 2800
Crankshaft
GE50008 Locator, crankshaft seal 2300, 2500, M

2800
GE50009 Bolt, crankshaft seal 2300, 2500, M

installer (use with GE50008) 2800
GE50010 Distorter, protection ring 2300, 2500, M

(use with GE50008) 2800
GE50011 Distorter tool (use with 2300, 2500, M

GE50008) 2800
GE50012 Installer, front crankshaft 2300, 2500, M

seal (use with GE500008) 2800
GE50013 Installer, rear crankshaft 2300, 2500, M

seal (use with GE50008) 2800
GE50014 Nut (use with GE50008) 2300, 2500, M

2800
Note
76
Contents
2300 –2500 & 2800
Electrical
CH11169 Terminal insertion / 2300, 2500, R

extraction tool 2800
CH11155 Crimp tool for harness 2300, 2500, R

repair kits 2800
GE50036 Service bypass harness 2300, 2500, R

2800
GE50037 70 pin breakout harness 2300, 2500, R

(replaces 2900A025) 2800
GE50038 Engine timing probe 2300, 2500, M

2800
GE50039 Timing probe adaptor 2300, 2500, M

2800
GE50040 Deutsch "DT" timing probe 2300, 2500, M

cable 2800
GE50041 3 pin DT breakout harness 2300, 2500, M

(replaces 2900A024) 2800
supercedes to Part
No.CVT0019
GE50042 Signal reading probe 2300, 2500, M
2800
Note
Contents
2300 –2500 & 2800
General
GE50000 Installer, cylinder liner 2300, 2500, R

2800
GE50001 Remover, cylinder liner 2300, 2500, R

2800
GE50002 Cylinder liner projection 2300, 2500, R

height tool 2800
GE50003 Piston ring compressor - 2800 M

GE50005 Clamp bolt, cylinder liner 2300, 2500, R

(26 required) 2800
GE50006 Washer (26 required) 2300, 2500, R

2800
GE50007 Fibre washer (26 required) 2300, 2500, R

2800
GE50045 Piston ring compressor - 2300, 2500 M

2300 Series and
2500 Series
CH12090 Piston ring compressor - 2800-18 M

VP12712 Lift bracket, cylinder 2300, 2500, M

2800
Note
78
Contents
2300 –2500 & 2800
General continued
CH11148 Engine turning tool 2300, 2500, M

2800
CH11147 Oil sampling tool kit, 2300, 2500, M

contains: adaptor CH10820, 2800
sampling valve CH10822,
dust cap CH10821, O-Ring
CH10133, O-Ring CH10047
KRP1752 Oil sample kit, contains: 2300, 2500, M

sampling adaptor, sample 2800
bottles, self adhesive labels
CH11150 Essential maintenance tool 2300, 2500, R

kit, contains: engine turning 2800
tool CH11148, injector
setting tool CH11149, oil
sampling tool CH11147,
oil sampling kit KRP1572,
toolbox CH11305
27610308 Surface reconditioning pad 2506 R
27610309 Seal installer 2506 R
27610311 Slide hammer- crankshaft 2506 R

27610312 Camshaft bearing pilot 2506 R
27610313 Taper lock stud 2506 R
27610314 Puller plate 2506 R
Note
Contents
2300 –2500 & 2800
General continued
27610315 Alignment bush 2506 R
27610316 Backup plate 2506 R
27610317 Bolt 2506 R
27610318 Spacer plate 2506 R
27610319 Bearing tool 2506 R
27610321 Camshaft alignment tool 2506 R
GE50031 Pressurising pump, coolant 2300 / 2800 R

system
GE50032 Thermometer, coolant 2300 / 2800 R

temperature
GE50033 Pressure gauge 2300 / 2800 R
Note
80
Contents
4000 Series
Cylinder Head
T6253/156 Injector bush coning tool R

(use with 21825589)
T85002/14B Injector bush depth gauge R
T85002/2 Injector bush inserting tool R
T85002/58 Injector bush expanding R

tool (upper)
T6253/307 Fuel injector extractor R
T6253/356 Revised injector test R

adaptor 14.00mm plunger
T6253/353 Fuel injector setting tool M

large spring injectors
FIE
T6253/146 Injector clamp and fuel feed M

adaptor
T6253/146B Spare set of "O"-rings M
Note
Contents
4000 Series
FIE continued
T6253/172 Fuel setting tool (early M

engines)
T6253/147 Injector compressor kit M
T6253/177 Fuel setting tool (later M

engines)
T85002/14B Injector bush depth gauge R
T85002/2 Injector bush inserting tool R
T85002/58 Injector bush expanding R

tool (upper)
27610178 Cylinder head spark plug R

thread cleaning kit
T6253/202 Injector nozzle cleaning R

tools
T6253/208 Nozzle test master / injector R

tester
T6253/138 Dummy fuel injector R
T85002/2 Injector bush inserting R

guide
Note
82
Contents
4000 Series
Crankshaft
T6253/140 Rear oil seal insertion kit M

(use with 21825639)
T6253/141 Front oil seal insertion kit M

(4006) use with 21825577
T6253/141A Front oil seal insertion kit M

(4008)
T6253/209 Crankshaft pulley extractor M
T85316/1 Front oil insertion kit M
T6253/200 Crankshaft pulley extractor M
T6253/214 TV Damper removal kit R
27610179 Flywheel support studs R
T6253/157 Support studs - flywheel & R

damper
T85001/34 Crankshaft lifting bracket R
Note
Contents
4000 Series
T6253/141 Front oil seal insertion kit 4006 M

(4006) use with 21825577
T6253/161 Oil seal insertion kit 4016 series M
27610180 Rear oil seal insertion kit M
Note
84
Contents
4000 Series
Electrical
838/22 Timing calibration pick up 4016 E61TRS M

probe
27610213 Electronic service tool 4016 E61TRS M
Y03/00031 DCG Electronic governor M

cable & dongle
Y06/00012 Level 6 dongle kit M
Y06/00013 Level 2 dongle kit M
T6253/241 Heinzmann PG01 test unit M
27610208 TIPSS M
680/220 USB dongle level 6 M
680/219 USB dongle level 2 M
Note
Contents
4000 Series
General
SE254 Engine turning tool M
T6253/139 Piston ring compressing R

tool (use with 21825577)
T6253/200 Liner clamp kit R
T6253/295 Piston removal tool M
T6253/152 Liner extractor M
27610176 Spare retaining clip for Gas R

spark plug removal tool
T6253/350 Injector puller R
T85002/3 Valve guide inserting bush R
484/49 Multi torch plug remover R
T6253/152 Liner extractor M
Note
86
Contents
4000 Series
General continued
27610190 Spark plug removal tool Gas M
27610177 Detonation sensor removal 4016 E61TRS M

tool
27610183 Spare retaining clip 4016 E61TRS M

detonation removal tool
SE671K 30 Degree indicator socket M

tool
T85002/4 Valve seat inserting tool R
T6253/151 Cam bearing removal / R

refitting tool
T85001/33 Gear spacing tool R
T6253/236 Lifting eye R
T6253/154 Cylinder head lifting tool R
T6253/238 Circlip pliers - internal R
Note
Contents
4000 Series
General continued
T6253/256 Piston ring pliers R
T6253/139 Piston ring compressing R

tool
T9142/8 Cup plug mandrel R
T6253/144 Timing disc R
T6253/149 1/2” core plug inserter R
T6253/212 Piston crown handle M
Note
88
Contents
New Content
Cylinder Head
T400027 Rocker arm spacer tool - 6 1204 / 6E R

required on 6 litre products &
4 required on 4 litre products
FIE
T400015 Fuel pump locking pin, locks 1200 Series M

pump for removal / refitting
with engine at TDC
T400006 For access to fuel line 1200 Series M

connectors - Snapon
U4668898ANM
Timing
T400014 Engine timing pin, locks 1106D, 1200 M

crankshaft at TDC Series
Crankshaft
T400011 Engine barring tool - fixes 1100D / M

T400016 Bayonet front end oil seal 1200 Series M

fitting / removal tool - all 1200
Series engines with steel
front covers
Note
Contents
New Content
Crankshaft
T400017 Timing case cover alignment 1206E / 7.1 M

tool for 6 cylinder 1200 Series
products with steel timing case
cover
T400018 Centralising dolly for cast 1206E / 7.1 R

T400022 Timing case cover 1204E M

1200 Series product
T400023 Centralising dolly for cast 1204E R

27610217 FEOS fitting tool 1106D short R

nose crank,
1206 Series
T400021 Twin turbocharger 1206E R

alignment tool
Twin turbocharger 1204E R

alignment tool
Electrical
CA3 Series 3 communications All M

adaptor electronically
controlled
products
Note
90
Contents
New Content
After treatment
T400005 Spark plug bore, wire brush 1200 Series R
T400026 Spark indicator (ground 1200 Series R

lead also required)
T400031 Spark indicator grounding 1200 Series R

lead
T400025 RF sensor lead connector 1200 Series R
Note

Tooling Catalogue NAV-2011

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Tooling Catalogue NAV-2011

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Tool

21825510 Checking gauge, fuel pump

21825513 Adaptor, fuel pump timing

21825515 Adaptor, fuel pump timing -

21825528 Injector Analyser

21825578 Plate, crankshaft front oil

21825579 Sleeve, crankshaft front oil

21825580 Plate, crankshaft front oil

21825581 Crankshaft front oil seal

21825593 Replacer, camshaft front

21825607 Angle gauge

21825611 Wrench, fuel pump solenoid

21825615 Replacer tool for pistons

21825617 Dial gauge

21825619 Crankshaft pulley remover

21825620 Front oil seal protector

21825621 Front oil seal protector

21825623 Valve stem replacer

21825624 Installer, idler gear shaft

21825625 Installer, idler gear shaft

21825626 Installer, idler gear shaft

21825639 Driving handle

21825680 Fuel pump spill pipe

21825739 Valve spring compressor

21825765 Tool holder, injector sleeve

21825767 Cutter, injector sleeve face

21825768 Reamer, injector sleeve face

21825771 Remover, injector sleeve

21825776 Tube expander (pattern "C"

21825807 Spanner, crankshaft hub

21825844 Distance piece, cylinder liner

21825849 Slide hammer 2000 / 3000

21825854 Adaptor kit, injector remover

21825883 Ballizer, injector sleeve 3000

21825901 Wrench, governor drain

21825902 Lapping tool, cylinder liner

21825914 Remover, injector 2000

21825918 Wrench, spark plug sleeve

21825920 Wrench, drive coupling

21825922 Remover, injector & injector

21825925 Adaptor, valve guide replacer

21825927 Adaptor, valve spring

21825928 Adaptor, valve spring

21825930 Fuel pump and

21825933 Adaptor, valve spring

21825934 Valve spring

21825936 Centraliser, timing

21825938 Adjustable valve seat

21825941 Adaptors, cylinder

21825942 Adaptor, cylinder liner

21825947 Probe, piston

21825951 Socket, lower idler

21825952 Plunger timing pin

21825953 Installer, front oil seal

21825956 Adaptor, cylinder liner

21825959 Kit, liner holding

21825960 Remover kit, injector

21825963 Installer, rear oil seal

21825964 Spanner, for flange

21826012 Installer, nozzle

27610016 Adaptor, valve spring

27610021 Replacer tool for idler

27610022 Replacer, front oil

27610025 Adaptor / remover,