1104D Perkins NJ

RENR9525-01
June 2009
Disassembly and
Assembly
1104D Industrial Engine
NH (Engine)
NJ (Engine)
This document is printed from SPI. 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 premature failures, product damage, personal injury or
death.
RENR9525-01
Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump - Remove and Install (Electric
Fuel Priming Pump) .............................................. 5
Fuel Priming Pump - Remove and Install (Manual
Priming Pump) ...................................................... 6
Fuel Filter Base - Remove and Install (Secondary
Fuel Filter) ............................................................. 8
Fuel Transfer Pump - Remove ................................ 9
Fuel Transfer Pump - Install ................................... 11
Fuel Manifold (Rail) - Remove and Install ............. 13
Fuel Injection Lines - Remove ............................. 16
Fuel Injection Lines - Install ................................. 17
Fuel Injection Pump - Remove ............................ 18
Fuel Injection Pump - Install ................................ 21
Fuel Injection Pump Gear - Remove .................... 23
Fuel Injection Pump Gear - Install ........................ 25
Electronic Unit Injector - Remove ......................... 26
Electronic Unit Injector - Install ............................. 30
Turbocharger - Remove (Top Mounted Turbocharger
) ........................................................................... 35
Turbocharger - Remove (Side Mounted
Turbochargers) .................................................... 37
Turbocharger - Install (Top Mounted Turbocharger
) ........................................................................... 38
Turbocharger - Install (Side Mounted
Turbochargers) .................................................... 40
Wastegate Solenoid - Remove and Install ............ 41
Exhaust Manifold - Remove and Install (Top Mounted
Exhaust Manifold) ............................................... 42
Exhaust Manifold - Remove and Install (Side
Mounted Exhaust Manifold) ................................ 44
Exhaust Elbow - Remove and Install ................... 45
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 46
Inlet and Exhaust Valves - Remove and Install .... 50
Engine Oil Filter Base - Remove and Install ........ 52
Engine Oil Cooler - Remove ................................. 54
Engine Oil Cooler - Install ..................................... 55
Engine Oil Relief Valve - Remove and Install (Engines
with a Balancer Unit) ........................................... 56
Without a Balancer Unit) ..................................... 57
Engine Oil Pump - Remove and Install (Engines
Without a Balancer Unit) ..................................... 58
Water Pump - Remove ......................................... 61
Water Pump - Install ............................................. 62
Water Temperature Regulator - Remove and Install
............................................................................. 63
Flywheel - Remove ............................................... 64
Flywheel - Install ................................................... 65
Crankshaft Rear Seal - Remove ........................... 66
Crankshaft Rear Seal - Install ............................... 67
Flywheel Housing - Remove and Install .............. 68
Crankshaft Pulley - Remove and Install (Engines
With an Automatic Belt Tensioner) ...................... 70
Without an Automatic Belt Tensioner) ................. 71
Crankshaft Front Seal - Remove and Install ......... 72
3
Table of Contents
Front Cover - Remove and Install ......................... 73

Gear Group (Front) - Remove and Install ............. 75
Idler Gear - Remove ............................................. 78
Idler Gear - Install ................................................. 82
Housing (Front) - Remove .................................... 87
Housing (Front) - Install ........................................ 89
Accessory Drive - Remove ................................... 91
Accessory Drive - Disassemble ........................... 92
Accessory Drive - Assemble ................................ 92
Accessory Drive - Install ....................................... 93
Crankcase Breather - Remove and Install (Filtered
Breather) ............................................................. 94
Crankcase Breather - Remove and Install (Unltered
Breather) ............................................................. 96
Valve Mechanism Cover - Remove and Install ..... 96
Valve Mechanism Cover Base - Remove and
Install ................................................................... 98
Rocker Shaft and Pushrod - Remove ................. 101
Rocker Shaft - Disassemble .............................. 102
Rocker Shaft - Assemble ................................... 103
Rocker Shaft and Pushrod - Install ..................... 104
Cylinder Head - Remove .................................... 105
Cylinder Head - Install ........................................ 109
Lifter Group - Remove and Install ........................ 112
Camshaft - Remove and Install .......................... 113
Camshaft Gear - Remove and Install ................. 115
Camshaft Bearings - Remove and Install ........... 117
Engine Oil Pan - Remove and Install (Aluminum and
Pressed Steel Oil Pans) ..................................... 119
Engine Oil Pan - Remove and Install (Cast Iron Oil
Pan) .................................................................. 121
Balancer - Remove ............................................. 124
Balancer - Install ................................................. 126
Piston Cooling Jets - Remove and Install ........... 129
Pistons and Connecting Rods - Remove ............ 130
Pistons and Connecting Rods - Disassemble ..... 131
Pistons and Connecting Rods - Assemble ......... 132
Pistons and Connecting Rods - Install ................ 134
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................. 136
Connecting Rod Bearings - Install (Connecting rods
in position) ......................................................... 137
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position) ..................................... 139
Crankshaft - Remove .......................................... 143
Crankshaft - Install .............................................. 146
Crankshaft Timing Ring - Remove and Install .... 149
Crankshaft Gear - Remove and Install .............. 150
Bearing Clearance - Check ................................. 152
Crankshaft Position Sensor - Remove and
Install ................................................................. 153
Position Sensor (Fuel Injection Pump) - Remove and
Install ................................................................. 153
Coolant Temperature Sensor - Remove and
Install ................................................................. 154
Engine Oil Pressure Sensor - Remove and Install
........................................................................... 156
Fuel Pressure Sensor - Remove and Install ....... 157
Boost Pressure Sensor - Remove and Install ..... 158
4
Table of Contents
RENR9525-01
Inlet Air Temperature Sensor - Remove and

Install ................................................................. 159
Glow Plugs - Remove and Install ....................... 160
V-Belts - Remove and Install (Engines Without an
Automatic Belt Tensioner ) ................................ 161
Alternator Belt - Remove and Install (Engines With
an Automatic Belt Tensioner) ............................ 162
Fan - Remove and Install ................................... 163
Fan Drive - Remove and Install ......................... 164
Electronic Control Module - Remove and Install .. 165
ECM Mounting Bracket - Remove and Install ..... 168
Alternator - Remove (Engines Without an Automatic
Belt Tensioner) .................................................. 169
Alternator - Remove (Engines With an Automatic Belt
Tensioner) ......................................................... 170
Alternator - Install (Engines Without an Automatic
Belt Tensioner) .................................................. 170
Alternator - Install (Engines With an Automatic Belt
Tensioner) ......................................................... 171
Electric Starting Motor - Remove and Install ..... 171
Air Compressor - Remove and Install ................ 172
Vacuum Pump - Remove and Install .................. 177
Index Section
Index ................................................................... 178
RENR9525-01
5
Disassembly and Assembly

Section
i02933646
Fuel Priming Pump - Remove

and Install
(Electric Fuel Priming Pump)
Removal Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct training.
Illustration 1
g01269003
Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, General Hazard Information and High Pressure Fuel
Lines for safety information.
Typical example
Refer to Systems Operation, Testing and Adjusting Manual, Cleanliness of Fuel System Components for detailed information on the standards
of cleanliness that must be observed during ALL
work on the fuel system.
4. Disconnect plastic tube assembly (1) and plastic

tube assembly (2) from electric priming pump (4).
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before opening any compartment or disassembling any component containing uids.
Dispose of all uids according to local regulations and
mandates.
Note: Put identication marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent uid loss
and this helps to keep contaminants from entering
the system.
1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFF
position.
3. Disconnect harness assembly (3) from electric

priming pump (4).
Note: If the tube assemblies have quick t

connections, ensure that the connections are clean
before the tube assemblies and the electric priming
pump are plugged.
5. Remove bolts (5) from electric priming pump (4).
6. Remove electric priming pump (4) from the
mounting bracket.
Installation Procedure
NOTICE
6
RENR9525-01
1. Ensure that the electric priming pump is clean and

free from wear or damage. If necessary, replace
the electric priming pump.
i02933647
Fuel Priming Pump - Remove

and Install
(Manual Priming Pump)
Removal Procedure
NOTICE
Illustration 2
g01269003
Typical example
2. Position electric priming pump (4) on the mounting

bracket. Install bolts (5) to the electric priming
pump.
3. Tighten bolts (5) to a torque of 9 Nm (79 lb in).
4. Remove all plugs from plastic tube assembly (1),
plastic tube assembly (2) and electric priming
pump (4). Connect plastic tube assembly (1) and
plastic tube assembly (2) to electric priming pump
(4).
before the tube assemblies are connected.
5. Connect harness assembly (3) to electric priming
pump (4).
NOTICE
mandates.
the system.
6. Turn the fuel supply to the ON position.

7. Turn the battery disconnect switch to the ON
position.
8. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, Fuel System
- Prime.
RENR9525-01
7
NOTICE
Illustration 3
g01753133
Typical example
1. Ensure that the fuel priming pump is clean and

the fuel priming pump.

2. Drain primary lter (7). Refer to Operation and
Maintenance Manual, Fuel System Primary Filter
(Water Separator) Element - Replace.
3. Disconnect plastic tube assemblies (1).
before the tube assemblies are plugged.
4. Remove primary lter (7) from fuel priming pump
(4). Refer to Operation and Maintenance Manual,
Fuel System Primary Filter (Water Separator)
Element - Replace.
5. Remove bolts (6) from fuel priming pump (4).
Remove fuel priming pump (4) from the mounting
bracket.
Illustration 4
6. If necessary, follow Step 6.a through Step 6.c in

order to disassemble the fuel priming pump.
a. Remove connectors (2) from fuel priming pump
(4).
g01753133
Typical example
2. If necessary, follow Step 2.a through Step 2.d in

order to assemble fuel priming pump (4).
b. Remove plugs (5) from fuel priming pump (4).
a. Install new O-ring seals (3) to connectors (2)

and plugs (5).
c. Remove O-ring seals (3) from connectors (2)

and plugs (5).
b. Install connectors (2) to fuel priming pump (4).

c. Install plugs (5) to fuel priming pump (4).
d. Tighten the plugs and the connectors to a
torque of 20 Nm (14 lb ft).
8
RENR9525-01
3. Position fuel priming pump (4) on the mounting

bracket. Install bolts (6) to the fuel priming pump .
Tighten the bolts to a torque of 44 Nm (32 lb ft).
4. Remove plugs from plastic tube assemblies (1).
Connect plastic tube assemblies (1) to connectors
(2).
5. Install a new primary lter (7) to fuel priming pump
(4). Refer to Operation and Maintenance Manual,
Fuel System Primary Filter (Water Separator)
Element - Replace.
- Prime.
i02933636
NOTICE
mandates.
the system.
2. If necessary, remove the boost pressure sensor.
Refer to Disassembly and Assembly, Boost
Pressure Sensor - Remove and Install.
Fuel Filter Base - Remove and

Install
(Secondary Fuel Filter)
Removal Procedure
Table 1
Required Tools
Tool
Part Number
Part Description
Strap Wrench
Qty
1
NOTICE
Illustration 5
g01247416
Typical example
3. Disconnect plastic tube assemblies (3), (5) and (6)

from fuel lter base (1).
before the tube assemblies and the fuel lter base
are plugged.
4. Remove tube assembly (4), if equipped.
5. Use Tooling (A) in order to remove fuel lter (7).
Refer to Operation and Maintenance Manual,
Fuel System Secondary Filter - Replace.
RENR9525-01
9
6. Remove bolts (2) from fuel lter base (1). Remove

the fuel lter base from the cylinder head.
Note: Do not attempt to disassemble the fuel lter
base.
4. If necessary, install the boost pressure sensor.

Refer to Disassembly and Assembly, Boost
5. Install tube assembly (4), if equipped. Tighten the
nuts to a torque of 9 Nm (80 lb in).
NOTICE
NOTICE
Ensure that the plastic tube assemblies are installed
in the original positions. Failure to connect the plastic
tube assemblies to the correct ports will allow contamination to enter the fuel system. Contaminated fuel will
cause serious damage to the engine.
6. Remove plugs from plastic tube assemblies (3),

(5), and (6) and fuel lter base (1). Connect plastic
tube assemblies (3), (5) and (6) to fuel lter base
(1).

1. Ensure that the fuel lter base is clean and free

from damage. If necessary, replace the complete
fuel lter base assembly.

- Prime.
i02933650
Fuel Transfer Pump - Remove

Removal Procedure
Start By:
a. Remove the mounting bracket for the electronic
control module. Refer to Disassembly and
Assembly, ECM Mounting Bracket - Remove and
Install.
Illustration 6
g01247416
Typical example
2. Position fuel lter base (1) onto the cylinder head.

Install bolts (2). Tighten the bolts to a torque of
22 Nm (16 lb ft).
3. Install a new fuel lter (7) to fuel lter base (1).
Fuel System Secondary Filter - Replace for the
correct procedure.
NOTICE
10
RENR9525-01
NOTICE
mandates.
5. Remove the plastic tube assembly from outlet

connection (2).
6. Remove outlet connection (2) from fuel transfer
pump (4). Plug the open port in the fuel transfer
pump immediately with a new plug. Remove the
O-ring seal from the connection.
If necessary, remove inlet connection (7) from
fuel transfer pump (4). Plug the open port in the
fuel transfer pump immediately with a new plug.
Remove the O-ring seal from the connection.

the system.
2. If necessary, disconnect the hose for the
crankcase breather from the clip that secures the
hose to the engine oil pan. Position the hose away
from the fuel transfer pump.
Illustration 8
g01457480
7. Loosen banjo bolt (3) and banjo bolt (8). Remove

tube assembly (9) for the fuel return from the
cylinder head to the fuel transfer pump.
Note: Disconnect the tube assembly at the fuel
transfer pump rst in order to drain the fuel from the
cylinder head.
8. Remove banjo bolt (3) and sealing washers (10)
from tube assembly (9).
Illustration 7
g01247425
9. Remove banjo bolt (8) and sealing washers (10)

from tube assembly (9).
Typical example
3. If necessary, disconnect the harness assembly

from position sensor (1). Refer to Disassembly
and Assembly, Position Sensor (Fuel Injection
Pump) - Remove and Install. Position the harness
assembly away from the fuel transfer pump.
10. Use an allen wrench with a ball end in order

to remove allen head bolts (6) that secure fuel
transfer pump (4) to fuel injection pump (5).
Note: If the tube assembly has quick t connections,

ensure that the connections are clean before the tube
assembly is plugged.
4. Disconnect the plastic tube assembly from inlet
connection (7) on the fuel transfer pump.
RENR9525-01
11
i02933648
Fuel Transfer Pump - Install

NOTICE
Illustration 9
g01254881
11. Remove the fuel transfer pump from fuel injection

pump (5).
Note: Do not remove dowels (11) from the fuel
injection pump.
1. Ensure that the faces of the fuel injection pump
and the fuel transfer pump are clean and free
from damage. Replace any components that are
damaged.
Illustration 10
g01254883
12. Remove O-ring seal (12) from fuel transfer pump

(4).
Illustration 11
g01254883
2. Install a new O-ring seal (12) for fuel transfer

pump (4).
12
Illustration 12
RENR9525-01
g01254881
Illustration 14
g01457480
6. Install banjo bolt (8) and new sealing washers (10)

to tube assembly (9).
7. Install banjo bolt (3) and new sealing washers (10)
8. Install tube assembly (9) to the fuel return to fuel
transfer pump (4) and to the cylinder head. Tighten
banjo bolt (3) and banjo bolt (8) to a torque of
22 Nm (16 lb ft).
Illustration 13
g01247425
9. If necessary, install a new O-ring seal to inlet

connection (7). Install inlet connection (7) to fuel
transfer pump (4). Tighten the connection to
3. Align fuel transfer pump (4) with dowels (11) in

fuel injection pump (5). Install the fuel transfer
pump to the fuel injection pump.
Note: If the tube assembly has quick t connections,

ensure that the connections are clean before the tube
assembly is connected.
4. Use an allen wrench with a ball end to install allen

head bolts (6). Tighten the allen head bolts to a
10. Install the plastic tube assembly to outlet

5. Install a new O-ring seal to outlet connection (2).

Install outlet connection (2) to fuel transfer pump
(4). Tighten the connection to torque of 15 Nm
(11 lb ft).
11. Install the plastic tube assembly to inlet

12. If necessary, connect the harness assembly to
position sensor (1). Slide the locking tab into the
locked position.
13. If necessary, connect the hose for the crankcase
breather to the clip that secures the hose to the
engine oil pan.
14. Install the mounting bracket for the electronic
Install.
RENR9525-01
13
15. Install the electronic control module. Refer to

Disassembly and Assembly, Electronic Control
Module - Remove and Install.
- Prime.
i02933644
Fuel Manifold (Rail) - Remove

and Install
Removal Procedure
NOTICE
mandates.
the system.
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, Fuel Injection Lines
- Remove.
Contact with high pressure fuel may cause uid

penetration and burn hazards. High pressure fuel spray may cause a re hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
NOTICE
Illustration 15
g01243702
The fuel manifold is shown with fuel injection lines in position.
14
RENR9525-01
Note: The fuel pressure relief valve should only be

removed at Position (X). The fuel pressure relief
valve is a two-piece assembly which should not be
disassembled.
6. Remove bolts (2) from fuel manifold (1). Note the
position of any brackets that are secured by the
bolts.
7. Remove fuel manifold (1) from mounting bracket
(8).
8. If necessary, remove the bolts and remove
mounting bracket (8).
Table 2
Required Tools
Illustration 16
g01763053
1. If necessary, remove fuel pressure sensor (4).

Refer to Disassembly and Assembly, Fuel
2. If fuel pressure sensor (4) does not require
removal, slide locking tab (3) into the unlocked
position. Disconnect the plug on harness assembly
(7) from fuel pressure sensor (4).
3. Disconnect tube assembly (6) from fuel pressure
relief valve (5). The tube assembly can be secured
with a nut or with a banjo bolt. Immediately cap
the open port in the pressure relief valve with a
new cap. Immediately plug the open end of the
tube assembly with a new plug.
4. If tube assembly (6) is secured with a banjo bolt,
remove banjo bolt (9) and sealing washers (10).
Refer to Illustration 16.
Tool
Part
Number
27610294
Part Description
Injector Pipe Nut Tool
Qty
1
NOTICE
1. Ensure that all ports on the fuel manifold are
capped. Ensure that the fuel manifold is externally
clean and free from damage.
Note: Do not install a fuel manifold that has not
been capped. All caps must be left in place until the
fuel injection lines or the fuel pressure sensor are
installed.
Illustration 17
g01800633
5. If necessary, remove fuel pressure relief valve (5).

Use a deep socket in order to remove the fuel
pressure relief valve.
RENR9525-01
15
6. Use Tooling (A) to tighten the nuts on the fuel

injection lines to a torque of 30 Nm (22 lb ft). Refer
to Disassembly and Assembly, Fuel Injection
Lines - Install for more information.
Illustration 20
Illustration 18
g01243702
g01800633
7. If necessary, install a new fuel pressure relief valve

(5). Use a deep socket in order to tighten the fuel
pressure relief valve. Tighten the fuel pressure
relief valve to a torque of 120 Nm (89 lb ft).
Note: Fuel pressure relief valve (5) must only be
tightened at Position (X). The fuel pressure relief
valve is a two-piece assembly which should not be
disassembled.
8. Remove the plug from tube assembly (6). Remove
the cap from the appropriate port in fuel manifold
(1). Connect tube assembly (6) to fuel pressure
relief valve (5). If tube assembly (6) is secured
with a nut, tighten the nut to a torque of 26 Nm
(19 lb ft). Refer to Illustration 18.
9. If tube assembly (6) is secured with a banjo bolt,
install new sealing washers (10) and install banjo
bolt (9). Tighten the banjo bolt to a torque of
21 Nm (186 lb in).
Illustration 19
g01763053
2. If necessary, install mounting bracket (8) and

install the bolts. Tighten the bolts to a torque of
22 Nm (16 lb ft).
3. Position fuel manifold (1) onto mounting bracket
(8). Install bolts (2) to the fuel manifold nger tight.
Ensure that any brackets that are secured by bolts
(2) are installed in the correct position.
10. If fuel pressure sensor (4) was removed from

fuel manifold (1), install a new sealing washer
and install the fuel pressure sensor. Refer to
Disassembly and Assembly, Fuel Pressure
Sensor - Remove and Install for more information.
If fuel pressure sensor (4) was not removed from
fuel manifold (1), connect the plug on harness
assembly (7) to fuel pressure sensor (4). Slide
locking tab (3) into the locked position.
- Prime for more information.
4. Loosely install a new set of fuel injection lines.

Refer to Disassembly and Assembly, Fuel
Injection Lines - Install for more information.
5. Tighten bolts (2) to a torque of 22 Nm (16 lb ft).
16
RENR9525-01
i02933638
Fuel Injection Lines - Remove

position.
Removal Procedure
Table 3
Required Tools
Tool
Part Number
U5MK1124
Part Description
Cap Kit
Qty
1

NOTICE
Illustration 21
g01457355
Typical example
3. Disconnect fuel injection line (3) from electronic

unit injector (2).
4. Disconnect fuel injection line (3) from fuel manifold
(4).
5. Remove fuel injection line (3). Discard the fuel
injection line.
6. Plug the open port in fuel manifold (4) immediately.
Use Tooling (A) in order to plug the open port.
7. Remove seal (1) from electronic unit injector (2)
and from the base of the valve mechanism cover.
NOTICE
8. Use a new plug in order to plug the open port in

electronic unit injector (2). Use Tooling (A) in order
to plug the open port.

mandates.
10. If necessary, remove the crankcase breather.

Refer to Disassembly and Assembly, Crankcase
Breather - Remove and Install.

the system.
11. Remove the electronic control module. Refer to

9. Repeat Step 3 through Step 8 in order to

remove the remaining fuel injection lines from the
electronic unit injectors.
RENR9525-01
17
NOTICE
g01254886
Illustration 22
Typical example
12. Remove bolt (7) from clip (8).

13. Disconnect fuel injection line (6) from fuel injection
pump (5).
Note: The following procedure should be adopted

in order to install the fuel injection lines when the
electronic unit injectors or the fuel manifold have
not been removed. If the electronic unit injectors
or the fuel manifold have been removed, refer to
Disassembly and Assembly, Electronic Unit Injector
- Install and Disassembly and Assembly, Fuel
Manifold (Rail) - Remove and Install for more
information.
14. Disconnect fuel injection line (6) from fuel

manifold (4).
15. Remove fuel injection line (6). Discard the fuel
injection line. Plug all open ports immediately. Use
Tooling (A) in order to plug the open ports in the
fuel manifold and in the fuel injection pump.
i02933637
Fuel Injection Lines - Install

Table 4
Required Tools
Tool
Part Number
27610294
Part Description
Qty
1
Illustration 23
g01254886
Typical example
1. Remove the caps from the port in fuel injection

pump (5) and from the appropriate port in fuel
manifold (4). Remove the caps from the new fuel
injection line (6).
2. Loosely connect the nuts at both ends of fuel
injection line (6), to fuel manifold (4) and to fuel
injection pump (5). Ensure that the ends of the
fuel injection line are correctly seated in the fuel
injection pump and in the fuel manifold.
18
RENR9525-01
3. Use Tooling (B) to tighten the nuts on fuel injection

line (6) to a torque of 30 Nm (22 lb ft).
8. Remove the caps from the new fuel injection line

(3).
4. Install bolt (7) to clip (8). Tighten bolt (7) to a

Note: Ensure that a dust seal is installed to the fuel

injection line. Install the fuel injection line for number
one cylinder rst. Install the fuel injection lines in
numerical order.
Ensure that fuel injection line does not contact

any other engine component.
5. Install the electronic control module. Refer to
6. If necessary, install the crankcase breather.
9. Remove the caps from electronic unit injector (2)

and from the appropriate port in fuel manifold (4).
10. Loosely connect the nuts at both ends of fuel
injection line (3), to electronic unit injector (2) and
to the appropriate port in fuel manifold (4). Ensure
that the ends of the fuel injection line are correctly
seated in the electronic unit injector and in the
fuel manifold.
11. Use Tooling (B) to tighten the nuts on fuel injection
line (3) to a torque of 30 Nm (22 lb ft). Ensure that
the dust seal is seated correctly against seal (1).
12. Follow Step 7 through Step 11 in order to install
the remaining fuel injection lines.
Note: Ensure that fuel injection lines do not contact
position.
15. Remove the air from the fuel system. Refer
to Operations and Maintenance Manual, Fuel
System - Prime.
Illustration 24
g01457387
i03458261
Typical example
Fuel Injection Pump - Remove

Removal Procedure
Table 5
Required Tools
Tool
Part Number
A(1)
21825576
Crankshaft Turning Tool
27610291
Barring Device Housing
27610289
Gear
27610212
Camshaft Timing Pin
27610211
Crankshaft Timing Pin
U5MK1124
Cap Kit
A(2)
Illustration 25
g01271377
Typical example
The valve mechanism cover is not shown for clarity.
7. Install a new seal (1) to electronic unit injector (2)

and to valve mechanism cover base (13).
(1)
(2)
Part Description
Qty
Install Tooling to the front pulley.

Install Tooling into the aperture for the electric starting motor.
Note: Ensure that the ange on the seal is ush with

the valve mechanism cover base.
RENR9525-01
Start By:
a. Remove the electronic control module. Refer to
b. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.

NOTICE
19
3. If necessary, remove the fuel lter base. Refer to

Disassembly and Assembly, Fuel Filter Base Remove and Install.
4. If necessary, remove the fuel priming pump. Refer
to Disassembly and Assembly, Fuel Priming
Pump - Remove and Install.
5. If necessary, remove the crankcase breather.
6. Use Tooling (A) in order to rotate the crankshaft so
that number one piston is at the top center position
on the compression stroke. Refer to Systems
Operation, Testing and Adjusting, Finding Top
Centre Position for No.1 Piston.
7. Use Tooling (B) in order to lock the camshaft in
the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, Gear Group (Front)
- Remove and Install for the correct procedure.
8. Remove the backlash from the fuel pump gear.
Lock the fuel injection pump in the correct
position and remove the fuel pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear Remove for the correct procedure.
NOTICE
mandates.
the system.
Illustration 26
g01563275
Typical example

position.
20
RENR9525-01
17. Remove tube assembly (8) for the engine oil

supply to the fuel injection pump. Remove the
banjo bolt and the sealing washers from the tube
assembly.
Illustration 27
g01563276
Typical example
9. Disconnect plastic tube assembly (2) from fuel

injection pump (1).
10. Disconnect harness assembly (6) from solenoid
(3). Slide the locking tab into the unlocked position
and disconnect harness assembly (6) from
position sensor (7).
Illustration 28
g01566973
Typical example
18. Remove bolts (15) and remove bolt (16). Remove

support bracket (14).
Note: The harness assembly should be positioned

in order to avoid an obstruction to the fuel injection
pump.
injection pump (1).
injection pump (1).
injection pump (1).
14. Remove banjo bolt (13) and remove sealing
washers (12).
15. Plug or cap all open ports and tube assemblies
immediately with new plugs or caps.
Note: Ensure that quick t connections are clean
Illustration 29
g01801934
Typical example
16. Remove fuel injection line (5). Refer to

- Remove. Use Tooling (D) in order to plug the
open ports in the fuel injection pump and in the
fuel manifold. Discard the fuel injection line.
19. Remove bolts (18) and remove sealing washers

(19).
Note: The fuel injection pump should be supported
by hand as the bolts are removed.
RENR9525-01
21
20. Carefully remove fuel injection pump (1) from

front housing (20). Ensure that bore (X) in the
front housing is not damaged as the fuel injection
pump is removed.
21. Remove O-ring seal (17) from fuel injection pump
(1).
i03401825
Fuel Injection Pump - Install

Table 6
Required Tools
Tool
Part
Number
A(1)
21825576
27610291
27610289
Gear
27610212
Camshaft Timing Pin
27610211
27610352
Fuel Injection Pump

Timing Tool
21820221
POWERPART
Rubber Grease
A(2)
(1)
(2)
Part Description
Qty
The Crankshaft Turning Tool is used on the front pulley.

This Tool is used in the aperture for the electric starting motor.

Illustration 30
g01572496
Typical example
Note: A new fuel injection pump is supplied,

locked in the correct position. Do not unlock the
fuel injection pump before installation.
1. If the fuel injection pump timing has been lost, it
is possible to reset the fuel injection pump timing.
Follow Step 1.a through Step 1.e in order to reset
the fuel injection pump timing.
a. Loosen locking screw (22) and slide spacer
(21) to Position (AA). Tighten locking screw
(22) to a torque of 9 Nm (80 lb in). This will
prevent the locking screw from tightening
against the shaft of the fuel injection pump.
The fuel injection pump is now unlocked.
NOTICE
b. Position Tooling (E) onto the shaft of fuel

injection pump (1). Align the lever of Tooling
(E) with Keyway (Y) and engage the lever into
the keyway.
Note: The lever of Tooling (E) should be a close t in
the keyway. If the lever is a loose t in the keyway, it
is not possible to reset the fuel injection pump timing.
c. Rotate the shaft of the fuel injection pump and
engage the pin of Tooling (E) into Hole (Z).
The fuel injection pump timing is now set in the
correct position.
d. Loosen locking screw (22) and slide spacer
(21) to Position (BB). Tighten locking screw
(22) to a torque of 9 Nm (80 lb in). The locking
screw is now tightened against the shaft of the
fuel injection pump.
The fuel injection pump is now locked.
22
RENR9525-01
Note: Ensure that the fuel injection pump is unlocked

after the installation of fuel injection pump gear is
completed.
e. Remove Tooling (E).
9. Install the front cover. Refer to Disassembly and

Illustration 31
g01801934
Typical example
2. Inspect Bore (X) in front housing (20) for

damage. If the bore is damaged, replace the front
housing. Refer to Disassembly and Assembly,
Housing (Front) - Remove and Disassembly and
Assembly, Housing (Front) - Install.
3. Use Tooling (F) to lubricate a new O-ring seal (17).
Install the O-ring seal onto fuel injection pump (1).
4. Align fuel injection pump (1) with front housing
(20). Carefully install the fuel injection pump to the
front housing.
Illustration 32
g01566973
Typical example
10. Position support bracket (14) and install bolts (15)

nger tight. Install bolt (16) nger tight.
11. Tighten bolt (16) to a torque of 44 Nm (32 lb ft).
Tighten bolts (15) to a torque of 22 Nm (16 lb ft).
Note: The fuel injection pump should be supported

by hand until the bolts are installed.
5. Install bolts (18) and new sealing washers (19).
6. If necessary, use Tooling (A) in order to rotate the
crankshaft so that number one piston is at top
dead center on the compression stroke. Refer to
System Operation, Testing and Adjusting, Finding
Top Centre Position for No.1 Piston.
7. Use Tooling (B) in order to lock the camshaft in
the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, Gear Group (Front)
8. Install the fuel injection pump gear to the fuel
injection pump. Refer to Disassembly and
Assembly, Fuel Injection Pump Gear - Install
and refer to Disassembly and Assembly, Gear
Group (Front) - Install.
Illustration 33
g01563276
Typical example
RENR9525-01
23
20. If necessary, install the crankcase breather.

21. If necessary, install the fuel priming pump. Refer
to Disassembly and Assembly, Fuel Priming
22. If necessary, install the fuel lter base. Refer to
Disassembly and Assembly, Fuel Filter Base Remove and Install.
position.
i02933643
Fuel Injection Pump Gear Remove

Illustration 34
g01563275
Typical example
Removal Procedure
12. Install the banjo bolt and new sealing washers

to tube assembly (8). Install tube assembly (8)
for the oil feed to the fuel injection pump. Tighten
the banjo bolt and the nut to a torque of 15 Nm
(11 lb ft).
Table 7
13. Install a new fuel injection line (5). Refer to

- Install.
Required Tools
Tool
Part Number
A(1)
21825576
27610291
27610289
Gear
27610212
Camshaft Timing Pin
27610211
Puller (Three Leg)
A(2)
14. Install new sealing washers (12) and banjo bolt

(13) to tube assembly (11). Tighten the banjo bolt
to a torque of 21 Nm (15 lb ft).
15. Connect plastic tube assembly (4) to fuel injection
pump (1).
pump (1).
17. Connect plastic tube assembly (10) to fuel
injection pump (1).
18. Connect harness assembly (6) to solenoid (3).
Connect harness assembly (6) to position sensor
(7). Slide the locking tab into the locked position.
pump (1).
(1)
(2)
Part Descriptions
Qty

Start By:
a. Remove the front cover. Refer to Disassembly and
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
24
RENR9525-01
NOTICE
mandates.
Note: Care must be taken in order to ensure that
the fuel injection pump timing is not lost during the
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.
Illustration 36
g01459153
Typical example
4. Apply sufcient pressure to fuel injection pump

gear (2) in a counterclockwise direction in order
to remove the backlash. Lock fuel injection pump
(3) in this position.
In order to lock fuel injection pump (3), loosen
locking screw (4) in the fuel injection pump. Slide
spacer (5) into Position (YY). Tighten locking
screw (4) against the shaft of the fuel injection
pump to a torque of 9 Nm (80 lb in).
Illustration 35
g01459155
Typical example
2. Install Tooling (B) through Hole (X) in camshaft

gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position.
3. Install Tooling (C) into Hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in
the correct position.
Note: Do not use excessive force to install Tooling
(C). Do not use Tooling (C) to hold the crankshaft
during repairs.
Illustration 37
g01765133
Alignment of timing marks
5. Mark gear (1), gear (2) and gear (7) in order to

show alignment. Refer to Illustration 37.
Note: Identication will ensure that the gears can be
installed in the original alignment.
6. Loosen nut (6) on fuel pump gear (2).
RENR9525-01
25
7. Install Tooling (D) through three holes in fuel pump

gear (2). Tighten Tooling (D) until the fuel pump
gear is released.
2. Ensure that Tooling (C) is installed in Hole (Y) in

the front housing. Use Tooling (C) in order to lock
the crankshaft in the correct position.
8. Remove Tooling (D) from fuel pump gear (2).
3. Ensure that Tooling (B) is installed into Hole (X) in

camshaft gear (1).
9. Remove nut (6) and the washer from fuel pump

gear (2). Remove the fuel pump gear.
i02933642
Fuel Injection Pump Gear Install
4. Ensure that shaft (8) on the fuel injection pump is

clean, dry and free from damage.
5. Ensure that the fuel injection pump is locked in
the correct position. Refer to Disassembly and
Assembly, Fuel Injection Pump - Install.
6. Ensure that the fuel pump gear is clean, dry and
the fuel pump gear.
Table 8
Required Tools
Tool
Part Number
27610212
Camshaft Timing Pin
27610211
21825617
Dial Indicator Group
Finger Clock
Part Description
Qty
NOTICE
Illustration 39

component life.
Note: The fuel injection pump must remain locked
until the procedure instructs you to unlock the fuel
injection pump.
g01769115
7. Install fuel pump gear (2) to shaft (8) of the fuel

injection pump. Ensure that the timing marks on
gears (2) and (7) are in alignment and that the
mesh of the gears is correct.
1. Ensure that number one piston is at the top

center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting,
Finding Top Center Position for No. 1 Piston.
Illustration 40
g01769133
Typical example
Illustration 38
g01765193
Typical example
26
RENR9525-01
i02933618
Electronic Unit Injector Remove

Removal Procedure
Table 9
Required Tools
Tool
Part Number
A(1)
21825576
27610291
27610289
Gear
27610307
T40 Torx Socket
27610288
Pry Bar
A(2)
Illustration 41
g01459724
Typical example
8. Install a new spring washer (9) and install nut

(6) to shaft (8) of the fuel injection pump. Apply
sufcient pressure to fuel injection pump gear (2)
in a counterclockwise direction in order to remove
the backlash. Tighten nut (6) to a torque of 25 Nm
(18 lb ft). Unlock fuel injection pump (3).
In order to unlock the fuel injection pump, loosen
locking screw (4) on the fuel injection pump. Slide
spacer (5) into Position (ZZ). Tighten the locking
screw against the spacer to a torque of 9 Nm
(80 lb in). This will prevent the locking screw from
tightening against the shaft of the fuel injection
pump.
9. Remove Tooling (B) and Tooling (C).
(1)
(2)
Part Description
Qty

Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

10. Tighten nut (6) to a torque of 90 Nm (66.4 lb ft).

11. Use Tooling (E) to measure the backlash of gears
(2) and (7). Ensure that the backlash for the gears
is within specied values. Refer to Specications,
Gear Group (Front) for further information.
12. Lubricate the teeth of the gears with clean engine
oil.
End By:
a. Install the front cover. Refer to Disassembly and
NOTICE
RENR9525-01
27
NOTICE
mandates.
NOTICE
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
incorrect tooling will result in damage to the electronic
unit injectors.
the system.
4. Follow Step 4.a through Step 4.d in order to gain

access to the electronic unit injector.
a. Make a temporary mark on valve bridges (5) in
order to show the location and orientation.
Note: Identication will ensure that the valve bridges
can be reinstalled in the original location and the
original orientation.
b. Loosen nuts (3) for the appropriate cylinder.
Unscrew adjusters (2) for the appropriate
cylinder until pushrods (4) can be withdrawn
from the balls of the adjusters.
c. Withdraw the cups of pushrods (4) from the
balls of adjusters (2).
d. Remove valve bridges (5) from the cylinder
head. If the valve bridges are equipped with
shrouds (6), ensure that the shrouds are
removed from the cylinder head.
Note: Do not interchange the location or the
orientation of used valve bridges.

position.
Illustration 43
g01769493
Typical example
5. Loosen banjo bolt (8) on the fuel transfer pump

sufciently in order to allow the fuel to drain from
tube assembly (7).
Illustration 42
g01772534
Typical example
3. Use Tooling (A) in order to rotate the crankshaft

until rocker arms (1) for the appropriate cylinder
are in the correct position in order to adjust
the valve lash. Refer to Systems Operation,
Testing and Adjusting, Engine Valve Lash Inspect/Adjust.
28
Illustration 44
RENR9525-01
g01769513
Illustration 45
g01769553
The rocker shaft is not shown for clarity.
6. Remove the fuel injection line and remove seal

(9) from the appropriate electronic unit injector
(12). Refer to Disassembly and Assembly, Fuel
Injection Lines - Remove.
10. Use Tooling (C) to pry beneath clamp (14) and

free electronic unit injector (12) from the cylinder
head.
Note: Cap all open ports immediately with new caps.
11. Remove electronic unit injector (12) and clamp

(14) from the cylinder head.
7. Use a deep socket to remove connections (11)

from electronic unit injector (12).
Note: Always handle electronic unit injectors with

care.
8. Slide rocker arms (1) to one side in order to gain

access to torx screw (13). Use Tooling (B) in order
to remove the torx screw from clamp (14). Discard
the torx screw.
Note: Tooling (B) must be used to ensure no
damage to the rocker arms.
9. Place a temporary identication mark on the
original electronic unit injector. The electronic unit
injector must be reinstalled in the original location
in the cylinder head.
Illustration 46
g01769574
Typical example
12. Remove sealing washer (15). Ensure that the

sealing washer is removed from the cylinder head.
Remove O-ring seal (16) from the electronic unit
injector.
RENR9525-01
29
Alternative Removal Procedure

Table 10
Required Tools
Tool
Part Number
Part Description
Qty
27610307
T40 Torx Socket
27610288
Pry Bar
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
b. Remove the fuel injection lines. Refer to
- Remove.
NOTICE
unit injectors.
the system.
position.
Note: This is an optional procedure to remove the

electronic unit injectors. The method should ONLY be
used when all electronic unit injectors are removed
and when the engine is removed from the application.

Illustration 47
NOTICE
g01769493
Typical example
3. Loosen banjo bolt (8) on the fuel transfer pump

sufciently in order to allow the fuel to drain from
tube assembly (7).
NOTICE
mandates.
30
RENR9525-01
8. Use Tooling (C) to pry beneath clamp (14) and free

electronic unit injector (12) from the cylinder head.
9. Remove electronic unit injector (12) and clamp
Note: Always handle electronic unit injectors with
care.
Illustration 48
g01769513
Typical example
g01769574
Illustration 50
4. Place a temporary identication mark on

connections (11) for harness assembly (10).
from electronic unit injector (12).
6. Use Tooling (B) in order to remove torx screw (13)
from clamp (14). Discard the torx screw.
original electronic unit injector. The electronic unit
injector must be reinstalled in the original location
in the cylinder head.
Typical example
10. Remove sealing washer (15). Ensure that the

sealing washer is removed from the cylinder head.
Remove O-ring seal (16) from the electronic unit
injector.
11. Repeat Step 4 through Step 11 in order to remove
the remaining electronic unit injectors.
i02933617
Electronic Unit Injector - Install

Table 11
Required Tools
Tool
Part Number
27610307
T40 Torx Socket
GE50028
Vacuum Pump
GE50030
Tube
7.9 mm (0.31 inch)
Outside Diameter
27610294
27610296
Torque Wrench
Illustration 49
Part Description
Qty
g01769553
Typical example
RENR9525-01
31
NOTICE
1. If a replacement electronic unit injector is installed,

the correct trim le for the injector must be
programmed into the electronic control module.
Refer to Troubleshooting, Injector Trim File for
more information. The code that is required to
obtain the trim le for the injector is located at
Position (X).
Note: Record Code (X) before the electronic unit

injector is installed.
Note: Evacuate as much fuel as possible from the

cylinder before installing the electronic unit injector.
NOTICE
2. Use Tooling (D) in order to remove any fuel from

the cylinder.
3. Ensure that the fuel inlet port of the electronic unit

injector is capped. Ensure that the electronic unit
injector is clean.

mandates.
NOTICE
Use a deep socket in order to install the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic
unit injectors.
Illustration 52
g01769574
Typical example
4. On installing an original electronic unit injector,

install a new O-ring seal (16) and sealing washer
(15) to electronic unit injector (12).
Ensure that O-ring seal (16) and sealing washer
(15) on a new electronic unit injector are not
damaged and in place.
Note: Do not lubricate the O-ring seal.
5. Ensure that the seat for the electronic unit injector
in the cylinder head is clean and free from
damage. Ensure that the old sealing washer has
been removed from the cylinder head.
Illustration 51
g01772353
Typical calibration code
32
Illustration 53
RENR9525-01
g01769513
Illustration 54
g01772534
Typical example
6. Position clamp (14) between the rocker arm and

the valve springs. Align electronic unit injector (12)
to the bore for the electronic unit injector in the
cylinder head. Install the clamp to the electronic
unit injector. Ensure that the electronic unit injector
is pushed rmly against the seat in the cylinder
head.
7. Install a new torx screw (13) to clamp (14). Tighten
the torx screw nger tight.
8. Remove the cap from electronic unit injector (12).
Install a new seal (9) to electronic unit injector (12)
and to the valve mechanism cover base. Ensure
that the ange on the seal is ush with the valve
mechanism cover base.
9. Remove the plugs from the new fuel injection
line. Loosely install the fuel injection line. Refer to
- Install.
Note: Ensure that the ends of the fuel injection line
are seated in the electronic unit injector and the fuel
manifold. Tighten the nuts nger tight.
10. Use Tooling (B) to tighten torx screw (12) to a
Note: Tooling (B) must be used to ensure no
damage to the rocker arms.
11. Use Tooling (E) to tighten the fuel injection line to
a torque of 30 Nm (22 lb ft). Refer to Disassembly
and Assembly, Fuel Injection Lines - Install.
Illustration 55
g01774093
Typical example
The electronic unit injector is not shown for clarity.
NOTICE
Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference
between the pistons and the valves, resulting in damage to the engine.
12. Install valve bridges (5) to the cylinder head. If
valve bridges (5) are equipped with shrouds (6),
ensure that the shrouds are located correctly.
RENR9525-01
33
Note: Ensure that used valve bridges are reinstalled

in the original location and the original orientation.
Do not interchange the location or the orientation of
used valve bridges.
13. Ensure that the bottoms of the pushrods are
seated in the cups of the valve lifters. Locate the
balls of adjusters (2) into the cups of pushrods
(4). Adjust the valve lash. Refer to Systems
Operation, Testing and Adjusting, Engine Valve
Lash - Inspect/Adjust.
14. Use a deep socket to install harness assembly
(10) to electronic unit injector (12). Use Tooling (F)
to tighten connections (11) to a torque of 2.4 Nm
(21 lb in).
Alternative Installation Procedure

Table 12
Required Tools
Tool
Part Number
27610307
T40 Torx Socket
GE50028
Vacuum Pump
GE50030
Tube
7.9 mm (0.31 inch)
Outside Diameter
27610294
27610296
Torque Wrench
Part Description
Qty
Note: This is an optional procedure to install the

electronic unit injectors. The method should ONLY be
used when all electronic unit injectors are installed
and when the engine is removed from the application.
NOTICE
Illustration 56
g01769493
Typical example
15. Tighten banjo bolt (8) on the fuel transfer pump

for tube assembly (7). Tighten the banjo bolt to a
16. Install the valve mechanism cover. Refer to
position.
NOTICE
mandates.
NOTICE
unit injectors.
34
RENR9525-01
4. On installing an original electronic unit injector,

install a new O-ring seal (16) and sealing washer
(15) to electronic unit injector (12).
Ensure that O-ring seal (16) and sealing washer
(15) on a new electronic unit injector are not
damaged and in place.
Note: Do not lubricate the O-ring seal.
5. Ensure that the seat for the electronic unit injector
in the cylinder head is clean and free from
damage. Ensure that the old sealing washer has
been removed from the cylinder head.
Illustration 57
g01772353
Typical calibration code
1. If a replacement electronic unit injector is installed,

the correct trim le for the injector must be
programmed into the electronic control module.
Refer to Troubleshooting, Injector Trim File for
more information. The code that is required to
obtain the trim le for the injector is located at
Position (X).
Note: Record Code (X) before the electronic unit
injector is installed.
g01769513
2. Use Tooling (D) to remove any fuel from the

cylinder.
Illustration 59
Note: Evacuate as much fuel as possible from the

cylinder before installing the electronic unit injector.
6. Install clamp (14) to electronic unit injector (12).

Install the electronic unit injector assembly into the
original location in the cylinder head.
3. Ensure that the fuel inlet port of the electronic unit

injector is capped. Ensure that the electronic unit
injector is clean.
Typical example
Note: Ensure that the electronic unit injector is

pushed rmly against the seat in the cylinder head.
Install the electronic unit injector for number one
cylinder rst. Install the electronic unit injectors in
numerical order.
7. Install a new torx screw (13) to clamp (14). Tighten
the torx screw nger tight.
8. Remove the cap from electronic unit injector (12).
Install a new seal (9) to electronic unit injector (12)
and to the valve mechanism cover base. Ensure
that the ange on the seal is ush with the valve
Illustration 58
Typical example
g01769574
9. Remove the plugs from the new fuel injection

line. Loosely install the fuel injection line. Refer to
- Install.
RENR9525-01
35
Note: Ensure that the ends of the fuel injection line

are seated in the electronic unit injector and the fuel
manifold. Tighten the nuts nger tight.
10. Use Tooling (B) to tighten torx screw (12) to a
11. Use Tooling (E) to tighten the fuel injection line to
a torque of 30 Nm (22 lb ft). Refer to Disassembly
and Assembly, Fuel Injection Lines - Install.
12. Repeat Step 2 through Step 11 in order to install
the remaining electronic unit injectors.
13. Use a deep socket to install harness assemblies
(10) to electronic unit injectors (12). Use Tooling
(F) to tighten connections (11) to a torque of
2.4 Nm (21 lb in).
Illustration 61
g01769493
Typical example
16. Tighten banjo bolt (8) on the fuel transfer pump

for tube assembly (7). Tighten the banjo bolt to a
position.
i03428965
Turbocharger - Remove
(Top Mounted Turbocharger )
Illustration 60
g01774093
Removal Procedure
Typical example
The electronic unit injector is not shown for clarity.
NOTICE
valve bridges (5) are equipped with shrouds (6),
15. Install the rocker shaft assembly. Refer to
Pushrods - Install.
NOTICE
component life.
NOTICE
mandates.
Note: Plug and cap all open ports and tube
assemblies.
36
RENR9525-01
1. Disconnect the air hose for the turbocharger inlet

and for the turbocharger outlet.
2. If the turbocharger has a remote wastegate
solenoid, disconnect the hose from the actuator on
the turbocharger. Disconnect the hose assembly
for the wastegate solenoid from the tube assembly
for the oil feed on the turbocharger. The hose
assembly is secured with clips.
3. Disconnect the exhaust pipe.
4. If the turbocharger has an exhaust elbow, remove
the exhaust elbow. Refer to Disassembly and
Assembly, Exhaust Elbow - Remove and Install.
Illustration 63
g01782773
9. Loosen nuts (14).

10. Remove banjo bolt (11) and remove tube
assembly (2) for the oil feed from turbocharger
(13). Remove sealing washers (12).
11. Remove exhaust manifold (1) and the assembly
of the turbocharger from the cylinder head. Refer
to Disassembly and Assembly, Exhaust Manifold
12. Remove bolts (17) and remove tube assembly (6)
for the oil drain from turbocharger (11).
Illustration 62
g01780893
13. Remove gasket (15).
5. Remove bolts (10) in order to disconnect tube

assembly (6) from the cylinder block. Remove
gasket (8).
14. Remove nuts (14) and remove turbocharger (13)

from exhaust manifold (1).
6. Remove bolt (7) in order to disconnect tube

sealing washers (9).
Note: Ensure that the exhaust manifold and the

turbocharger are adequately supported during the
removal of the turbocharger.
7. Remove bolt (3) for the tube clip.
15. Remove gasket (16) from exhaust manifold (1).
8. Remove bolt (5) and spacer (4) for the tube clip.
16. If necessary, remove studs (18) from exhaust

manifold (1).
RENR9525-01
37
i02933674
Turbocharger - Remove
(Side Mounted Turbochargers)
Removal Procedure
NOTICE
component life.
NOTICE
mandates.
Note: Plug and cap all open ports and tube
assemblies.
1. Disconnect the air hose for the turbocharger inlet
and for the turbocharger outlet (not shown).
2. If the turbocharger is equipped with an exhaust
elbow, remove the exhaust elbow. Refer to
Disassembly and Assembly, Exhaust Elbow Remove and Install.
Illustration 64
g01264131
Typical example
3. If the turbocharger is equipped with an adapter

(9), Remove nuts (10) and remove adapter (9)
from turbocharger (5).
4. Remove banjo bolt (1) and disconnect tube
assembly (3) from turbocharger (5). Remove
sealing washers (2) from tube assembly (3).
If necessary, remove tube assembly (3) from the
tube assembly for actuator (6). Tube assembly (3)
is secured to the tube assembly for the actuator
by clips.
5. Disconnect the hose from actuator (6).
6. Remove banjo bolt (4) and remove tube assembly
(3) from the cylinder block. Remove sealing
washers (2) from tube assembly (3).
38
RENR9525-01
7. Remove bolts (12). Disconnect tube assembly

(13) from turbocharger (5). Remove gasket (11).
If necessary, remove bolts (14) and remove tube
gasket (15).
8. Remove nuts (8) and remove turbocharger (5).
Note: Do not use the actuator rod to lift the
turbocharger.
10. If necessary, remove the studs from the exhaust
manifold.
i03431780
Turbocharger - Install
(Top Mounted Turbocharger )
Illustration 65
g01784893
Typical example
Table 13
Required Tools
Tool
Part Number
Part Description
Qty
21820117
POWERPART
Threadlock and Nutlock
NOTICE
1. Ensure that the turbocharger is clean and free

from damage. Inspect the turbocharger for wear.
Refer to System Operation, Testing and Adjusting,
Turbocharger Inspect for more information. If the
turbocharger is worn, the complete turbocharger
must be replaced.
2. Test wastegate actuator (20) for correct operation.
Refer to System Operation, Testing and Adjusting,
Turbocharger Inspect. If the wastegate actuator
is damaged or the wastegate actuator does not
operate within the specied limits, the complete
turbocharger must be replaced.

component life.
RENR9525-01
39
11. Remove the plug from oil inlet port (19). Refer to
Illustration 65. Lubricate the turbocharger bearings
with clean engine oil through the oil inlet port.
Rotate the wheel of the compressor several times
in order to lubricate the bearings.
12. Ensure that tube assembly (2) is clean and free
from damage. Replace any damaged components.
13. Install banjo bolt (11) and new sealing washers
(12) to tube assembly (2).
Illustration 66
g01782773
3. Clean the gasket surfaces of the exhaust manifold

(1). If necessary, install studs (18) to the exhaust
manifold. Tighten the studs to a torque of 18 Nm
(13 lb ft).
Note: Support the exhaust manifold during
installation of the turbocharger.
4. Install a new gasket (16) to exhaust manifold (1).
5. Position turbocharger (13) on exhaust manifold
(1).
6. Install nuts (14). Tighten the nuts to a torque of
44 Nm (32 lb ft).
7. Ensure that tube assembly (6) is clean and free
from damage. Replace any damaged components.
8. Position a new gasket (15) and bolts (17) onto
tube assembly (6).
Illustration 67
g01780893
14. Install banjo bolt (7) and new sealing washers

(9) to tube assembly (2).
15. Install tube assembly (2) to turbocharger (13).
Tighten banjo bolt (11) nger tight. Refer to
Illustration 66.
16. Tighten banjo bolt (7) to the cylinder block nger
tight.
9. Install tube assembly (6) to turbocharger (13).

Tighten bolts (17) nger tight.
17. Position a new gasket (8) between the ange of

tube assembly (6) and the cylinder block. Install
bolts (10) nger tight.
10. Install exhaust manifold (1) and the assembly of

the turbocharger to the cylinder head. Refer to
Disassembly and Assembly, Exhaust Manifold Remove and Install for the correct procedure.
18. Tighten banjo bolt (7) to a torque of 20 Nm

(14 lb ft). Tighten bolts (10) to a torque of 22 Nm
(16 lb ft).
19. Tighten banjo bolt (11) to a torque of 20 Nm
(14 lb ft). Tighten bolts (17) to a torque of 9 Nm
(80 lb in). Refer to Illustration 66.
40
RENR9525-01
20. Install bolt (3) for the tube clip to the cylinder
block. Tighten bolt (3) to a torque of 44 Nm
(32 lb ft).
21. Install bolt (5) and spacer (4) for the tube clip to
the cylinder block. Tighten bolt (5) to a torque of
44 Nm (32 lb ft).
1. Ensure that the turbocharger is clean and free

from damage. Inspect the turbocharger for
wear. Refer to Systems Operation, Testing and
Adjusting, Turbocharger - Inspect for more
information. If the turbocharger is worn, the
complete turbocharger must be replaced.
22. If the turbocharger has an exhaust elbow, install

23. Connect the exhaust pipe.
24. If the turbocharger has a remote wastegate
solenoid, connect the hose to the actuator on the
turbocharger. Connect the hose assembly for the
wastegate solenoid to the tube assembly for the
oil feed on the turbocharger. The hose assembly
is secured with clips.
25. Connect the air outlet hose to turbocharger (13).
If the engine has an air pipe, install the air pipe
and install the gasket to the cylinder head. Apply
Tooling (A) to the fasteners for the air pipe. Tighten
the fasteners to a torque of 22 Nm (16 lb ft).
Tighten the hose clamps to a torque of 5 Nm
(44 lb in).
Note: If the air outlet hose has a reective heat
shield, ensure that the reective heat shield is
installed toward the engine.
26. Connect the air inlet hose to turbocharger (13).
i02933673
Turbocharger - Install
(Side Mounted Turbochargers)
Table 14
Illustration 68
g01264131
Typical example
Required Tools
Tool
Part Number
Part Description
Qty
21820117
POWERPART
NOTICE
component life.
2. Test actuator (6) for correct operation. Refer

Turbocharger - Inspect. If the actuator is
damaged or the actuator does not operate within
the specied limits, the complete turbocharger
must be replaced.
3. Clean the gasket surfaces of the exhaust manifold.
If necessary, install the studs to the exhaust
manifold. Tighten the studs to a torque of 18 Nm
(13 lb ft).
4. Install a new gasket (7) to the exhaust manifold.
RENR9525-01
41
5. Position turbocharger (5) onto the exhaust

manifold and install nuts (8). Tighten the nuts to a
Note: If the air outlet hose has a reective heat

shield, ensure that the reective heat shield is
installed toward the engine.
Note: Do not use the actuator rod to lift the

turbocharger.
17. Connect the air inlet hose to turbocharger (5).
6. Position a new gasket (11) and tube assembly (13)

onto turbocharger (5). Install bolts (12) nger tight.
7. Position a new gasket (15) onto the cylinder block.
Install bolts (14) nger tight.
8. Tighten bolts (12) to a torque of 9 Nm (80 lb in).
9. Lubricate the bearings of turbocharger (5) with
clean engine oil through the oil inlet port. Rotate
the shaft of the turbocharger in order to distribute
the lubricant.
10. Position tube assembly (3) onto turbocharger (5).
Install new washers (2) and banjo bolt (1) to tube
assembly (3). Tighten the banjo bolt nger tight.
i02933679
Wastegate Solenoid - Remove

and Install
Removal Procedure
Note: Put identication marks on all hoses, on
all hose assemblies, on wires and on all tube
assemblies for installation purposes. Plug all hose
assemblies and tube assemblies. This helps to keep
contaminants from entering the system.
11. Install new washers (2) and banjo bolt (4) onto
tube assembly (3). Connect the tube assembly to
the cylinder block. Tighten the banjo bolt nger
tight.
12. Tighten banjo bolts (1) and (4) to a torque of
18 Nm (13 lb ft).
Note: Ensure that the tube assembly does not come
into contact with any other engine components.
13. Connect the hose to actuator (6). If necessary,
secure tube assembly (3) to the tube assembly for
actuator (6). Tube assembly (3) is secured to the
tube assembly for the actuator by clips.
14. If the turbocharger has an exhaust elbow, install
15. If the turbocharger has an adapter (9), position
the adapter onto the turbocharger. Tighten three
nuts (10) progressively. Tighten the nuts to a
Note: Ensure that the adapter is square with the face
of the turbocharger.
16. Connect the air outlet hose to turbocharger (5).
If the engine has an air pipe, install the air pipe
and install the gasket to the cylinder head. Apply
Tooling (A) to the bolts for the air pipe. Tighten the
bolts to a torque of 22 Nm (16 lb ft).
Illustration 69
g01247498
Typical example
1. Follow Step 1.a through Step 1.d in order

to disconnect the harness assembly for the
wastegate solenoid.
a. Slide locking tab (1) into the unlocked position.
b. Disconnect plug (2) from the engine wiring
harness.
c. Cut cable straps (3).
Note: Identify the position of all cable straps for
installation purposes.
d. Remove harness assembly (4) from tube
assembly (5). The harness assembly is secured
to the tube assembly by plastic clips (6).
Tighten the hose clamps to a torque of 5 Nm

(44 lb in).
42
RENR9525-01
4. Tighten tube assembly (5) and tube assembly (8)

5. Secure tube assembly (8) to the tube assembly for
the oil feed for the turbocharger. Tube assembly
(8) is secured by spring clips.
Note: Ensure that the tube assemblies do not contact
Illustration 70
g01247569
Typical example
2. Disconnect tube assembly (5) from wastegate

solenoid (7).
3. Disconnect tube assembly (8) from wastegate
solenoid (7). Remove tube assembly (8) from the
tube assembly for the oil feed for the turbocharger.
Tube assembly (8) is secured to the tube assembly
for the oil feed for the turbocharger by spring clips.
Note: Tube assembly (8) must be loose in order
to release the tube assembly from the wastegate
solenoid.
Illustration 72
g01247498
Typical example
6. Follow Step 6 through Step 6.d in order to connect

the wire lead for the wastegate solenoid.
4. Remove bolts (9) and remove wastegate solenoid

(7) from the cylinder block.
a. Install harness assembly (4) to tube assembly

(5). The harness assembly is secured to the
tube assembly by plastic clips (6).
b. Connect plug (2) to the engine harness

assembly.
c. Slide locking tab (1) into the locked position.
d. Install new cable straps (3) to the previously
identied positions.
i02933629
Illustration 71
g01247569
Exhaust Manifold - Remove

and Install
(Top Mounted Exhaust
Manifold)
Typical example
1. Loosely install wastegate solenoid (7) to tube

assembly (5).
Removal Procedure
2. Loosely install tube assembly (8) to wastegate

solenoid (7).
1. Disconnect all hoses, tube assemblies and wire

leads from the turbocharger. Refer to Disassembly
and Assembly, Turbocharger - Remove for more
information.
3. Install bolts (9). Tighten bolts (9) to a torque of

44 Nm (32 lb ft).
RENR9525-01
43
Installation Procedure (Top

Mounted Exhaust Manifold)
Table 15
Required Tools
Illustration 73
Tool
Part Number
Part Description
Guide Stud
M10 by 100 mm
Qty
2
g01245092
Typical example
Illustration 75
g01245092
Typical example
Illustration 74
g01789673
Tightening sequence for the exhaust manifold
2. Loosen bolts (4) in reverse numerical order to the

sequence that is shown in Illustration 74.
1. Ensure that the exhaust manifold is clean and free

from damage. If necessary, replace the exhaust
manifold. Clean the gasket surface of the cylinder
head.
2. If necessary, install studs (2) to exhaust manifold
(3). Tighten the studs to a torque of 18 Nm
(13 lb ft).
Note: This will help prevent distortion of the exhaust

manifold.
3. Remove bolts (4) from exhaust manifold (3).
Note: Support the manifold as the bolts are removed.
4. Remove the assembly of exhaust manifold (3) and
the turbocharger.
5. Remove exhaust manifold gasket (1).
6. Remove the turbocharger from exhaust manifold
(3). Refer to Disassembly and Assembly,
Turbocharger - Remove for more information.
Illustration 76

manifold (3).
3. Install Tooling (A) to the cylinder head in Positions

(X). Refer to Illustration 76.
g01789677
44
RENR9525-01
4. Position a new exhaust manifold gasket (1) onto

Tooling (A).
Note: Ensure that the exhaust manifold gasket is
correctly oriented.
5. Install the tube assembly for the oil drain from
the turbocharger to the cylinder block. Refer to
Disassembly and Assembly, Turbocharger Install for more information.
6. Align exhaust manifold (3) with Tooling (A). Install
the exhaust manifold to the cylinder head.
7. Install new bolts (4) nger tight.
8. Remove Tooling (A). Install remaining bolts (4)
nger tight.
9. Tighten bolts (4) to a torque of 40 Nm (30 lb ft) in
the sequence that is shown in Illustration 76.
Illustration 77
End By:
g01789922
Typical example
a. Install the turbocharger. Refer to Disassembly and

Assembly, Turbocharger - Install.
i03440266
Exhaust Manifold - Remove

and Install
(Side Mounted Exhaust
Manifold)
Removal Procedure
Illustration 78
g01789982
Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, Turbocharger - Remove.
1. Loosen bolts (4) in reverse numerical order. Refer

to Illustration 78.
Note: This will help prevent distortion of the exhaust
manifold.
2. Remove bolts (4) from exhaust manifold (3).
Note: Support the manifold as the bolts are removed.
3. Remove exhaust manifold (3).
4. Remove exhaust manifold gasket (1).
manifold (3).
RENR9525-01
45
Installation Procedure (Side

Mounted Exhaust Manifold)
4. Position a new exhaust manifold gasket (1) onto

Tooling (A).
Table 16
Note: Ensure that the exhaust manifold gasket is

correctly oriented.
Required Tools
Tool
Part Number
Part Description
Guide Stud
M10 by 100 mm
Qty
5. Align exhaust manifold (3) with Tooling (A). Install

the exhaust manifold to the cylinder head.
6. Install new bolts (4) nger tight.

7. Remove Tooling (A). Install remaining bolts (4)
nger tight.
Tighten the bolts in the sequence that is shown in
Illustration 79.
End By:
a. Install the turbocharger. Refer to Disassembly and
Assembly, Turbocharger - Install.
i02933628
Illustration 79
g01790878
Exhaust Elbow - Remove and

Install
Removal Procedure
Illustration 81
Illustration 80
g01789922
Typical example
1. Ensure that the exhaust manifold is clean and free

from damage. If necessary, replace the exhaust
manifold. Clean the gasket surface of the cylinder
head.
2. If necessary, install studs (2) to exhaust manifold
(3). Tighten the studs to a torque of 18 Nm
(13 lb ft).
g01798993
Typical example
1. Remove bolts (7) and remove exhaust elbow (4)

from turbocharger (1). Note the orientation of the
exhaust elbow.
2. Remove nuts (5) and remove adapter (2).
3. If necessary, remove bolts (6) and remove support
bracket (3) from the cylinder block.
3. Install Tooling (A) to the cylinder head in Positions

(X). Refer to Illustration 79.
46
RENR9525-01
i02933660
Inlet and Exhaust Valve

Springs - Remove and Install
Removal Procedure
Table 17
Required Tools
Illustration 82
Tool
Part Number
g01798993
Typical example
1. Ensure that the exhaust elbow, the adapter and the

outlet of the turbocharger are free from damage.
Replace any components that are damaged.
2. Install adapter (2) to turbocharger (1).
C(1)
C(2)
(1)
3. Install nuts (5). Tighten the nuts progressively.

Tighten nuts (5) to a torque of 25 Nm (18 lb ft).
4. If necessary, install support bracket (3) to the
cylinder block and install bolts (6). Tighten the
5. Install bolts (7) nger tight.
6. Ensure that the gap between the turbocharger
and the exhaust elbow is evenly spaced.
(2)
Part Description
Qty
Circlip Pliers
21825739
Valve Spring Compressor
27610235
Adapter
27610295
Head
21825576
27610291
27610289
Gear

Start By:
Pushrod - Remove.
Note: Either Tooling (C) can be used. Use the Tooling
NOTICE
component life.
Note: The following procedure should be adopted in
order to remove the valve springs when the cylinder
head is installed to the engine. Refer to Disassembly
and Assembly, Inlet and Exhaust Valves - Remove
and Install for the procedure to remove the valve
springs from a cylinder head that has been removed
from the engine.
Note: Ensure that the appropriate piston is at the top
center position before the valve spring is removed.
Failure to ensure that the piston is at the top center
position may allow the valve to drop into the cylinder
bore.
NOTICE
Plug the apertures for the push rods in the cylinder
head in order to prevent the entry of loose parts into
the engine.
RENR9525-01
47
NOTICE
unit injectors.
position.
Illustration 84
g01469792
Typical example
Personal injury can result from being struck by

parts propelled by a released spring force.
Illustration 83
g01469791
Typical example
2. Follow Step 2.a through Step 2.h in order to

remove the harness assemblies for the electronic
unit injectors.
a. Place a temporary identication mark on
connections (1).
b. Use a deep socket to remove connections (1)
from electronic unit injectors (2).
c. Cut cable strap (3).
d. Disconnect plug (6) from harness assembly (4).
e. Use Tooling (A) to remove circlip (5).
f. From the outside of valve mechanism cover
base (7), push harness assembly (4) inward.
Withdraw the harness assembly from the valve
g. Remove O-ring seal (8) from harness assembly
(4).
h. Repeat Step 2.a through Step 2.g in order to
remove the remaining harness assembly.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all
recommended tooling to release the spring force.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
3. Follow Step 3.a through Step 3.d in order to
position the appropriate piston at top dead center.
a. Install Tooling (B) in position on the cylinder
head in order to compress a valve spring for
the appropriate piston.
b. Use Tooling (B) in order to compress valve
spring (11) and open the valve slightly.
Note: Do not compress the spring so that valve
spring retainer (10) touches the valve stem seal.
c. Use Tooling (C) in order to rotate the crankshaft
carefully, until the piston touches the valve.
Note: Do not use excessive force to turn the
crankshaft. The use of force can result in bent valve
stems.
48
d. Continue to rotate the crankshaft and gradually

release the pressure on Tooling (B) until the
piston is at the top center position. The valve
is now held in a position that allows the valve
spring to be safely removed.
Note: Valve springs must be replaced in pairs for the
inlet valve or the exhaust valve of each cylinder. If all
valve springs require replacement the procedure can
be carried out on two cylinders at the same time. The
procedure can be carried out on the following pairs of
cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one
pair of cylinders to another pair of cylinders.
RENR9525-01
Table 18
Required Tools
Tool
Part Number

spring retainer (10) touches the valve stem seal .
(2)
21825739
Adapter
Head
21825576
27610291
27610289
Gear
21820221
POWERPART
Rubber Grease
27610296
Torque Wrench
C(1)
(1)
Circlip Pliers
27610235
C(2)
4. Apply sufcient pressure to Tooling (B) in order to

allow removal of valve keepers (9).
Qty
27610295
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Part Description

Note: Either Tooling (C) can be used. Use the Tooling

Remove valve keepers (9).

5. Slowly release the pressure on Tooling (B).
NOTICE
6. Remove valve spring retainer (10) and remove

valve spring (11).

component life.
7. If necessary, remove the valve stem seals.

the remaining valve springs from the appropriate
cylinder.
9. Remove Tooling (B).
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
NOTICE
Plug the apertures for the push rods in the cylinder
head in order to prevent the entry of loose parts into
the engine.
NOTICE
unit injectors.
1. Inspect the valve springs for the correct length.
Refer to Specications, Cylinder Head Valves .
2. If necessary, install a new valve stem seal onto
the valve guide.
Note: The outer face of the valve guide must be
clean and dry before installing the valve stem seal.
RENR9525-01
49
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
Note: Valve springs must be replaced in pairs for the
inlet valve or the exhaust valve of each cylinder. If all
valve springs require replacement the procedure can
be carried out on two cylinders at the same time. The
procedure can be carried out on the following pairs of
cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one
pair of cylinders to another pair of cylinders.
Illustration 85
g01469792
Typical example
3. Install valve spring (11) onto the cylinder head.

Position valve spring retainer (10) onto valve
spring (11).
Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.
NOTICE
Illustration 86
4. Install Tooling (B) in the appropriate position on

the cylinder head in order to compress the valve
spring.
5. Apply sufcient pressure to Tooling (B) in order to
install valve keepers (9).
spring retainer (10) touches the valve stem seal .
Install the valve spring keepers.
6. Carefully release the pressure on Tooling (B).
Note: Ensure that the valve keepers are correctly
seated.
7. Repeat Step 2 through Step 6 for the remaining
valves.
g01469791
Typical example
9. Follow Step 9.a through Step 9.g in order to install

the harness assemblies for the electronic unit
injectors.
a. Ensure that harness assembly (4) and the bore
in the valve mechanism cover base (7) are
clean and free from damage.
b. Use Tooling (D) to lubricate a new O-ring
seal. Install new O-ring seal (8) onto harness
assembly (4).
c. From the inside of valve mechanism cover
base (7), push harness assembly (4) into the
valve mechanism cover base.
d. Use Tooling (A) to install circlip (5).
50
RENR9525-01
e. Connect plug (6) to harness assembly (4).

f. Use a deep socket to install connections (1) to
electronic unit injectors (2). Use Tooling (E) to
tighten the connections to a torque of 2.5 Nm
(22 lb in).
g. Install a new cable strap (3).
Note: Ensure that the cable straps conform to the
Perkins specication.
h. Repeat Step 9.a through Step 9.g in order to
install the remaining harness assembly.
position.

heads of the valves in order to identify the correct
position. Inlet valves have a recess in the center
of the head.
Note: Do not stamp the heads of the valve. Stamping
or punching the heads of the valves could cause the
valves to fracture.
3. Use a suitable lifting device to position the cylinder
head with the valve springs upward. The weight of
the cylinder head is approximately 56 kg (125 lb).
Note: Ensure that the cylinder head is kept on a
clean, soft surface in order to prevent damage to the
machined face.
End By:
a. Install the rocker shaft assembly. Refer to
Pushrods - Install.
i02933661
Inlet and Exhaust Valves Remove and Install

Removal Procedure
Table 19
Required Tools
Tool
Part Number
Part Description
Qty
21825666
27610235
Adapter
27610295
Head
Illustration 87
g01469809
Typical example
Start By:

a. Remove the cylinder head. Refer to Disassembly

and Assembly, Cylinder Head - Remove.
NOTICE


component life.
4. Install Tooling (A) in position on the cylinder head

in order to compress the appropriate valve spring.
1. Clean the bottom face of the cylinder head.

Check the depth of the valves below the face of
the cylinder head before the valve springs are
removed. Refer to Specications, Cylinder Head
Valves for the correct dimensions.
NOTICE
RENR9525-01
51
NOTICE
component life.
1. Clean all components of the cylinder head
assembly. Ensure that all ports, all coolant
passages and all lubrication passages in the
cylinder head are free from debris. Follow Step
1.a through Step 1.e in order to inspect the
components of the cylinder head assembly.
Replace any components that are worn or
damaged.
a. Inspect the cylinder head for wear and for
damage. Refer to Systems Operation, Testing
and Adjusting, Cylinder Head Inspect.
g01245105
Illustration 88
5. Apply sufcient pressure to Tooling (A) in order to

remove valve keepers (1).
spring retainer (2) touches valve stem seal (4).
6. Slowly release the pressure on Tooling (A).
7. Remove valve spring retainer (2). Remove valve
spring (3).
valves.
b. Inspect the valve seats for wear and for

damage. Refer to Specications, Cylinder
Head Valves for further information.
c. Inspect the valve guides for wear and for
damage. Refer to Specications, Cylinder
Head Valves and Systems Operation, Testing
and Adjusting, Valve Guide - Inspect for
further information.
d. Inspect the valves for wear and for damage.
Refer to Specications, Cylinder Head Valves.
e. Inspect the valve springs for damage and for
the correct length. Refer to Specications,
Cylinder Head Valves.
9. Remove Tooling (A).

10. Remove valve stem seals (4).
11. Use a suitable lifting device to carefully turn over
the cylinder head.
12. Remove valves (5).
Table 20
Required Tools
Tool
Part Number
Part Description
Qty
21825666
27610235
Adapter
27610295
Head
1
Illustration 89
g01245105
52
RENR9525-01
2. Lubricate the stems of valves (5) with clean engine

oil. Install valves (5) in the appropriate positions in
the cylinder head. Check the depth of the valves
below the face of the cylinder head. Refer to
Systems Operation, Testing and Adjusting, Valve
Depth - Inspect for more information.
3. Use a suitable lifting device to carefully turn over
the cylinder head. The weight of the cylinder head
is approximately 56 kg (125 lb).
NOTICE
7. Apply sufcient pressure to Tooling (A) in order to
install valve keepers (1).
spring retainer (2) touches valve stem seal (4).
Note: Ensure that all of the valves remain in place.

4. Install new valve stem seals (4) onto each of the
valve guides.
Note: The outer face of the valve guides must be
clean and dry before installing the valve stem seals.
5. Install valve spring (3) onto the cylinder head.
Position valve spring retainer (2) onto valve spring
(3).
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
8. Carefully release the pressure on Tooling (A).
valves.
10. Remove Tooling (A) from the cylinder head.
11. Use a suitable lifting device to position the
cylinder head on a support. Ensure that the heads
of the valves are not obstructed.
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02933621
Illustration 90
g01469809
Engine Oil Filter Base Remove and Install
Typical example
Removal Procedure
Table 21
Tool
Part Number

Required Tools
Part Description
Strap Wrench
Qty
1
Note: The oil lter may be installed vertically or the

oil lter may be installed horizontally.
6. Install Tooling (A) in the appropriate position on

the cylinder head in order to compress valve
spring (3).
RENR9525-01
53
NOTICE
Table 22
Required Tools

component life.
NOTICE
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the uid with suitable containers before
opening any compartment or disassembling any component containing uids.
Tool
Part Number
Part Description
Qty
21820117
POWERPART
NOTICE
component life.

mandates.
Illustration 92
g01254186
Typical example
Illustration 91
g01254186
Typical example
1. Ensure that the engine oil lter base is clean.

Clean the gasket surface of the cylinder block.
1. Use Tooling (A) to remove engine oil lter (3).

Engine Oil and Filter - Change.
2. If necessary, install a new O-ring seal (5) to plug

(6). Install plug (6) to engine oil lter base (2).
Tighten the plug to a torque of 12 Nm (106 lb in).
2. If the engine oil pressure sensor is located in

the engine oil lter base, remove the engine
oil pressure sensor. Refer to Disassembly and
Assembly, Engine Oil Pressure Sensor - Remove
and Install.
3. Install bolts (4) to engine oil lter base (2).
3. Remove bolts (4) and remove engine oil lter base

(2).
5. If the engine oil lter base has a spacer plate,
remove the spacer plate and remove the gasket.
Note: Mark the orientation of the spacer plate.
6. If necessary, remove plug (6) from engine oil lter
base (2). Remove O-ring seal (5) from the plug.
4. Install a new gasket (1) onto bolts (4). If the engine

oil lter base has a spacer plate, install the spacer
plate and a new gasket onto the bolts.
Note: Ensure the correct orientation of spacer plate.
5. Apply Tooling (B) to the threads of the bolts. Install
the assembly of the engine oil lter base to the
cylinder block.
7. If the engine oil pressure sensor is located in
the engine oil lter base, Install the engine oil
pressure sensor. Refer to Disassembly and
Assembly, Engine Oil Pressure Sensor - Remove
and Install.
54
RENR9525-01
8. Install a new engine oil lter (3). If necessary,

ll the engine oil pan to the correct level that is
indicated on the oil level gauge. Refer to Operation
and Maintenance Manual, Engine Oil and Filter
- Change.
i02933620
Engine Oil Cooler - Remove
2. Drain the engine lubricating oil into a suitable

container. Refer to Operation and Maintenance
Manual, Engine Oil and Filter - Change for the
correct procedure.
3. If necessary, remove the electric starting motor.
Refer to Disassembly and Assembly, Electric
Starting Motor - Remove and Install.
4. Position the engine wiring harness away from the
assembly of oil cooler (1). If necessary, cut the
cable strap.
Removal Procedure
Start By:
a. Remove the bracket for the Electronic Control
Module. Refer to Disassembly and Assembly,
ECM Mounting Bracket - Remove and Install.
NOTICE
Illustration 93
g01254472
Typical example
NOTICE
component life.
NOTICE
mandates.
1. Drain the coolant from the cooling system into
a suitable container. Refer to Operation and
Maintenance Manual, Cooling System Coolant Change for the correct procedure.
Illustration 94
g01254473
Tightening sequence for the engine oil cooler
RENR9525-01
55
5. Loosen bolts (7) in reverse numerical order to the

sequence that is shown in Illustration 94. Remove
bolts (7). Support the assembly of engine oil
cooler (1) as the bolts are removed.
Note: Bolts of different lengths are installed. Note
the correct position of the bolts. Note the position of
any brackets that are secured by the bolts. Do not
remove bolts (6) at this time.
6. Remove the assembly of oil cooler (1) from the
cylinder block.
1. Follow Step 1.a through Step 1.c in order to

assemble the engine oil cooler.
a. Ensure that cooler matrix (3) is clean and free
from damage. Ensure that housing (5) is clean
and free from damage. Replace any damaged
components.
b. Position new gasket (4) onto housing (5). Install
cooler matrix (3).
c. Install bolts (6) nger tight.
2. Clean the gasket surface of the cylinder block.

disassemble the engine oil cooler.
3. Install bolts (7) to the engine oil cooler.
a. Remove bolts (6).

b. Remove cooler matrix (3) from housing (5).
c. Remove gaskets (4).
Note: The bolts are different lengths. Ensure that the

different bolts are installed in the correct location.
Ensure that any brackets that are secured by the
bolts are installed in the correct location.
4. Install a new gasket (2) to the assembly of oil
cooler (1). Push bolts (7) through the holes in the
gasket.
i02933619
Note: The holes in the gasket have serrations that

hold the bolts captive.
Engine Oil Cooler - Install

NOTICE
component life.
Illustration 96
g01254473
Tightening sequence for the engine oil cooler
5. Install the assembly of oil cooler (1) to the cylinder

block. Tighten bolts (7) to a torque of 22 Nm
(16 lb ft). Tighten the bolts in the sequence that is
shown in Illustration 96.
Illustration 95
Typical example
g01254472
6. Place the engine wiring harness in the correct

position. If necessary, install a new cable strap.
56
RENR9525-01
7. If necessary, Install the electric starting motor.

Refer to Disassembly and Assembly, Electric
Starting Motor - Remove and Install.
8. Fill the cooling system to the correct level.
Cooling System Coolant - Change for the correct
procedure.
9. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, Engine Oil
and Filter - Change for the correct procedure.
End By:
a. Install the bracket for the Electronic Control
Module. Refer to Disassembly and Assembly,
ECM Bracket - Remove and Install.
i02933626
Engine Oil Relief Valve Remove and Install

(Engines with a Balancer Unit)
g01470291
Illustration 97
Typical example

Removal Procedure
Table 23
Required Tools
Tool
Part Number
Part Description
Telescopic Magnet
Qty

Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly , Engine Oil Pan - Remove and
Install.
NOTICE
component life.
1. Loosen cap (2). Carefully remove the cap from

balancer (1).
Note: The spring force will be released when the cap
is removed.
2. Remove spring (3) from the bore for the relief
valve in balancer (1).
3. Use Tooling (A) in order to remove plunger (4)
from the bore for the relief valve in balancer (1).
Table 24
Required Tools
Tool
Part Number
21820117
Part Description
Qty
Telescopic Magnet
POWERPART
RENR9525-01
57
End By:
NOTICE
component life.
a. Install the engine oil pan. Refer to Disassembly

and Assembly, Engine Oil Pan - Remove and
Install.
i02933627
Engine Oil Relief Valve Remove and Install

(Engines Without a Balancer
Unit)
Removal Procedure
Table 25
Required Tools
Tool
Part Number
Part Description
Telescoping Magnet
Qty
1
Start By:
Illustration 98
g01470291
Typical example


Install.
NOTICE
component life.
1. Ensure that all components are clean and free

from wear or damage. If necessary, replace any
components that are worn or damaged. If the
bore for the relief valve in balancer (1) is worn or
damaged, the complete assembly of the balancer
must be replaced.
2. Lubricate plunger (4) with clean engine oil. Install
plunger (4) and spring (3) into the bore for the
relief valve in balancer (1).
Note: The plunger must slide freely in the bore for
the relief valve.
3. Apply Tooling (B) to the threads of cap (2). Install
cap (2) to balancer (1). Tighten the cap to a torque
of 21 Nm (15 lb ft).
Note: Ensure that the spring is properly located
inside the plunger and the cap. Ensure that Tooling
(B) does not contaminate the bore for the relief valve
in balancer (1).
Illustration 99
g01470289
Typical example
58
RENR9525-01




1. Remove bolts (6) and suction pipe (7).
2. Remove gasket (5) (not shown) from the suction
pipe .
3. Loosen cap (2). Carefully remove cap (2) from the
housing of engine oil pump (1).
Note: The spring force will be released when the cap
is removed.
4. Remove spring (4) from the bore for the relief
valve in the housing of engine oil pump (1).
5. Use Tooling (A) to remove plunger (3) from the
bore for the relief valve in the housing of engine
oil pump (1).

components that are worn or damaged. If the
bore for the relief valve in the housing of engine
oil pump (1) is worn or damaged, the complete
assembly of the engine oil pump must be replaced.
2. Lubricate plunger (3) with clean engine oil. Use
long nose pliers to install plunger (3) and spring
(4) into the bore for the relief valve in the housing
of engine oil pump (1).
Note: The plunger must slide freely in the bore for
the relief valve.
3. Install cap (2) to engine oil pump (1). Tighten the
cap to a torque of 45 Nm (33 lb ft).
Note: Ensure that the spring is properly located
inside the plunger and the cap.
4. Install suction pipe (7) and a new gasket (5) (not
shown) to the assembly of the engine oil pump.
NOTICE
component life.
5. Install bolts (6). Tighten the bolts to a torque to

22 Nm (16 lb ft).
End By:
Install.
i02933625
Engine Oil Pump - Remove and

Install
(Engines Without a Balancer
Unit)
Removal Procedure
Start By:
Illustration 100
Typical example
g01470289

Install.
RENR9525-01
59
Note: This procedure is for the removal of the engine

oil pump on engines that are not equipped with
a balancer. Refer to Disassembly and Assembly,
Balancer - Remove for information on the removal
of the engine oil pump for engines that are equipped
with a balancer.
NOTICE
component life.
NOTICE
mandates.
g01470295
Illustration 102
Typical example
5. If necessary, remove bolts (9) and front cover

assembly (6). Remove outer rotor (7) from the
housing of engine oil pump (3).
Note: Do not remove dowels (8) and (10) from the
housing of the engine oil pump unless the dowels
are damaged.
Table 26
Required Tools
Tool
Illustration 101
g01255703
Typical example

2. Remove the gasket from the suction pipe.
3. Remove bolts (5). Remove the assembly of the
engine oil pump (3) from the cylinder block.
4. If necessary, remove pressure relief valve (4)
from the housing of engine oil pump (3). Refer to
Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install.
Part Number
21825617
-
Part Description
Qty
Finger Clock
Note: This procedure is for the installation of the

engine oil pump on engines that are not equipped
with a balancer. Refer to Disassembly and Assembly,
Balancer - Install for information on the installation
of the engine oil pump for engines that are equipped
with a balancer.
NOTICE
component life.
60
RENR9525-01
NOTICE
If any of the parts on the engine oil pump are worn or
damaged, the entire pump must be replaced.
1. Ensure that all components of the engine oil pump
are clean and free from wear or damage. Check
the clearance between the outer rotor of the oil
pump and the oil pump body. Check the clearance
between the outer rotor and the inner rotor.
Check the end play of the rotor. Refer to Systems
Operation, Testing and Adjusting, Engine Oil
Pump - Inspect. Replace the complete assembly
of the engine oil pump if any of the components
are worn or damaged.
Illustration 104
g01255703
Typical example
3. If necessary, install pressure relief valve (4). Refer

to Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install for further information.
4. Ensure that dowel (8) and dowel (10) are correctly
located in the housing of engine oil pump (3).
Position the assembly of the engine oil pump onto
the cylinder block.
Note: Ensure that the dowels in the housing of the
engine oil pump are aligned with the holes in the
cylinder block.
5. Install bolts (5). Tighten the bolts to a torque of
44 Nm (32 lb ft).
6. Install suction pipe (2) and a new gasket to the
assembly of the engine oil pump.
Illustration 103
g01470295
Typical example
2. If necessary, lubricate the internal components of

the assembly of the engine oil pump with clean
engine oil. Install outer rotor (7) and front cover
(6) to the housing of engine oil pump (3). Install
bolts (9). Tighten the bolts to a torque of 9.5 Nm
(84 lb in).

22 Nm (16 lb ft).
8. Use Tooling (A) in order to check the backlash
between the idler gear of the oil pump and the
crankshaft gear. Refer to Specications, Gear
Group - Front for further information.
End By:
Install.
RENR9525-01
61
i02933681
Water Pump - Remove

Removal Procedure
Start By:
a. Remove the fan and the fan pulley. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
NOTICE
component life.
NOTICE
mandates.
a suitable container for storage or disposal.
procedure.
2. Loosen the hose clamps and remove the hose
from the water pump inlet.
Illustration 105
g01263054
Typical example
3. Remove bolts (4). The bolts are different lengths.

Note the positions of the different bolts.
Note: Do not remove bolts (7) at this time.
4. Remove water pump (3) from front cover (1).
Note: If necessary, tap the water pump with a soft
hammer in order to loosen the water pump.
6. If necessary, remove cover (6) from the water
pump. Follow Step 6.a through Step 6.c in order
to remove the cover.
b. Remove cover (6).
c. Remove gasket (5).
62
RENR9525-01
i02933680
Water Pump - Install
b. Position a new gasket (5) onto water pump (3).

c. Install cover (6) to water pump (3).
d. Install bolts (7) to cover (6). Tighten the bolts
nger tight.
3. Clean the gasket surface of front cover (1).
Table 27
Required Tools
Tool
Part Number
Part Description
Guide Stud
M8 by 80 mm
Qty
2
NOTICE
component life.
1. Ensure that the water pump is clean and free from
wear or damage. If necessary, replace the water
pump.
Illustration 107
g01269392
4. Install Tooling (A) in Position (X).

5. Use Tooling (A) in order to align a new gasket (2)
to front cover (1). Install the gasket to the front
cover.
6. Align water pump (3) with Tooling (A). Install the
water pump to front cover (1).
Note: Ensure that the gear of the water pump and
the gear of the fuel injection pump mesh.
7. Install bolts (4). Refer to Illustration 106. Tighten
the bolts nger tight.
Note: Ensure that bolts of different lengths are
installed in the correct positions.
8. Remove Tooling (A) and install remaining bolts
(4) nger tight.
Illustration 106
g01269391
Typical example
2. If necessary, install cover (6) to water pump (3).

Follow Step 2.a through Step 2.d in order to install
the cover.
a. Clean the gasket surface of cover (6).
RENR9525-01
63
NOTICE
mandates.
1. Drain the coolant from the cooling system to a
level below the water temperature regulator, into
a suitable container for storage or for disposal.
draining procedure.
Illustration 108
g01269393
Tightening sequence for the water pump
9. Tighten bolts (4) and bolts (7) to a torque of 22 Nm

(16 lb ft). Refer to Illustration 106. Tighten the bolts
in the sequence that is shown in Illustration 108.
10. Install the hose to the water pump inlet. Tighten
the hose clamps securely.
11. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, Cooling
System Coolant - Change for the correct
procedure.
End By:
a. Install the fan and the fan pulley. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
i02933682
Water Temperature Regulator Remove and Install
Illustration 109
g01269478
Typical example
2. Loosen the hose clamps from the upper radiator

hose and disconnect the upper radiator hose from
water temperature regulator housing (2).
3. Remove bolts (1) from water temperature
regulator housing (2).
4. Remove water temperature regulator housing (2)
from the cylinder head.
Note: Note the orientation of the water temperature
regulator housing.
Removal Procedure
NOTICE
component life.
64
RENR9525-01
A new water temperature regulator housing is

supplied with a new O-ring seal.
3. Install water temperature regulator housing (2) to
the cylinder head.
Note: Ensure the correct orientation of the water
temperature regulator housing.
Illustration 110
g01269481
Typical example
5. Remove O-ring seal (3) from water temperature

regulator housing (2).
g01269478
Illustration 112
NOTICE
Typical example

component life.

44 Nm (32 lb ft).
5. Connect the upper radiator hose and tighten the
hose clamps securely.
6. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, Cooling
System Coolant Level - Check and Operation and
Maintenance Manual, Cooling System Coolant Change for the correct lling procedure.
i02933633
Flywheel - Remove
Illustration 111
g01263044
Typical example
1. Ensure that all components of water temperature

regulator housing (2) are clean and free of wear or
damage. Check the water temperature regulator
for correct operation. Refer to Systems Operation,
Testing and Adjusting, Water Temperature
Regulator - Test for the procedure to test the
water temperature regulator. If any components
of the water temperature regulator housing are
worn or damaged, the complete assembly must
be replaced.
2. If the original water temperature regulator housing
is installed, position a new O-ring seal (3) into the
groove in the water temperature regulator housing
(2). Ensure that locating tab (4) is correctly seated
in water temperature regulator housing (2).
Removal Procedure
Table 28
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
1/2 inch - 20 UNF by 4
inch
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
RENR9525-01
65
NOTICE
6. Inspect ywheel (1) and ring gear (3) for wear or

damage. Replace any components that are worn
or damaged.

component life.
7. To remove the ywheel ring gear, follow Step 7.a

and Step 7.b.
a. Place the ywheel assembly on a suitable
support.
Note: Identify the orientation of the teeth on the
ywheel ring gear.
b. Use a hammer and a punch in order to remove
ring gear (3) from ywheel (1).
i02933632
Flywheel - Install
Table 29
Required Tools
Illustration 113
g01245126
Typical example
Tool
Part Number
1. Remove two bolts from Positions (X) on ywheel

(1).
Part Description
Guide Stud
1/2 inch - 20 UNF by 4
inch
Qty
2
2. Install Tooling (A) to Positions (X) on ywheel (1).
NOTICE
3. Attach a suitable lifting device to ywheel (1).

Support the weight of the ywheel. The weight of
the ywheel is approximately 71 kg (155 lb).

component life.
4. Remove remaining bolts (2).

5. Use the lifting device in order to remove the
ywheel from the engine.
Illustration 115
g01470362
Typical example
Illustration 114
Typical example
g01245152
Always wear protective gloves when handling

parts that have been heated.
66
RENR9525-01
1. If the ywheel ring gear was removed, follow Step

1.a through Step 1.c in order to install a new ring
gear to the ywheel.
a. Identify the orientation of teeth (4) on new ring
gear (3).
Note: The chamfered side of the ring gear teeth must
face toward the starting motor when the ywheel is
installed. This will ensure the correct engagement of
the starting motor.
b. Heat ywheel ring gear (3) in an oven to a
maximum temperature of 250 C (482 F) prior
to installation.
Note: Do not use a torch to heat the ring gear.
c. Ensure that the orientation of ring gear (3) is
correct and quickly install the ring gear onto
ywheel (1).
6. Install bolts (2) to ywheel (1) nger tight.

7. Remove Tooling (A) and install remaining bolts
(2) to ywheel (1).
8. Remove the lifting device from ywheel (1).
9. Use a suitable tool to prevent the ywheel from
rotating. Tighten bolts (2) to a torque of 115 Nm
(85 lb ft).
10. Check the run out of the ywheel. Refer to
Specications, Flywheel for further information.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
i02933610
2. Inspect the crankshaft rear seal for leaks. If there

are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, Crankshaft
Rear Seal - Remove and Disassembly and
Assembly, Crankshaft Rear Seal - Install for the
correct procedure.
Crankshaft Rear Seal - Remove

Removal Procedure
Table 30
Required Tools
Tool
Part Number
Part Description
E12 Torx Socket
Qty
1
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
component life.
Illustration 116
g01245126
Typical example
3. Install a suitable lifting device to ywheel (1). The

weight of the ywheel is approximately 71 kg
(155 lb).
4. Install Tooling (A) to Positions (X) on the
crankshaft.
5. Use the lifting device in order to position ywheel
(1) onto Tooling (A).
NOTICE
mandates.
Note: The crankshaft rear seal and the housing
are manufactured as a one-piece assembly. The
assembly is not serviceable. If the crankshaft rear
seal is removed, the assembly must be replaced.
RENR9525-01
67
g01269512
Illustration 117
Illustration 118
g01258105
Illustration 119
g01255709
Typical example
1. Use Tooling (A) in order to remove torx screws (1)

from crankshaft rear seal (2).
2. Remove crankshaft rear seal (2) from the cylinder
block. Discard the crankshaft rear seal.
i02933609
Crankshaft Rear Seal - Install

Typical example
Table 31
1. Ensure that crankshaft ange (1) is clean, dry and

free from damage.
Required Tools
Tool
Part Number
27610306
Part Description
Qty
E12 Torx Socket
Alignment Tool
2. Ensure that the face of the cylinder block and the

bridge piece are clean and dry.
Note: The crankshaft rear seal and the housing are

manufactured as a one-piece assembly.
3. A new crankshaft rear seal is supplied with a

plastic sleeve (3). Ensure that the plastic sleeve is
squarely installed within crankshaft rear seal (2).
NOTICE
Note: The plastic sleeve is included in order to

protect the lip of the seal as the seal is pushed over
the crankshaft ange.

component life.
Note: Do not lubricate the crankshaft rear seal or

the crankshaft ange. The crankshaft rear seal
must be installed dry.
4. Align plastic sleeve (3) with crankshaft ange (1).
Ensure that the plastic sleeve is engaged onto the
crankshaft ange. Push new crankshaft rear seal
(2) squarely onto the crankshaft ange.
During this process, the plastic sleeve will be
forced out of the crankshaft rear seal. Discard the
plastic sleeve.
68
RENR9525-01
5. Align the two molded locators on crankshaft rear

seal (2) with the holes in the cylinder block. Ensure
that the crankshaft rear seal is seated against the
cylinder block.
i02933634
Flywheel Housing - Remove

and Install
Removal Procedure
Table 32
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
M10 by 100 mm
Start By:
a. Remove the ywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
Illustration 120
g01258357
Tightening sequence for the crankshaft rear seal

component life.
6. Install torx screws (4) nger tight.

Note: Do not install torx screws to Positions (X) at
this stage.
7. Install Tooling (B) to crankshaft rear seal (2) and
to crankshaft ange (1).
8. Use Tooling (A) in order to tighten torx screws (4)
to a torque of 22 Nm (16 lb ft). Tighten torx screws
(4) in the sequence that is shown in Illustration
120.
10. Install remaining torx screws (4) to Positions (X).
Use Tooling (A) in order to tighten the torx screws
to a torque of 22 Nm (16 lb ft). Refer to Illustration
120.
End By:
Illustration 121
a. Install the ywheel. Refer to Disassembly and

Assembly, Flywheel - Install.
g01470403
Typical example
1. Remove the bolts from Position (X) from ywheel

housing (1).
2. Install Tooling (A) into Position (X) on ywheel
housing (1).
3. Install a suitable lifting device to the ywheel
housing in order to support the ywheel housing.
The ywheel housing weighs approximately 30 kg
(66 lb).
RENR9525-01
69
Table 33
Required Tools
Tool
Part Number
21825617
Part Description
Qty
Guide Bolt
M10 by 100 mm
NOTICE
component life.
1. Ensure that the ywheel housing is clean and free
from damage. If necessary, replace the ywheel
housing.
Illustration 122
g01763013
Typical example
4. Remove bolts (2) and remaining bolts (3) from

ywheel housing (1).
5. Use the lifting device in order to remove ywheel
housing (1) from the cylinder block.
Illustration 124
g01244056
Typical example
2. Inspect crankshaft rear seal (6) for leaks. If there

are any oil leaks, replace the crankshaft rear seal.
Rear Seal - Remove and refer to Disassembly
and Assembly, Crankshaft Rear Seal - Install.
Illustration 123
g01470418
Typical example
3. Clean the rear face of the cylinder block. If

necessary, install dowels (4) to the cylinder block.
6. If the engine has an aluminum oil pan, remove

dust seal (5).
4. Install Tooling (A) to the cylinder block.
7. If necessary, remove dowels (4) from the cylinder

block.
5. Install dust seal (5).
70
RENR9525-01
i02933607
Crankshaft Pulley - Remove

and Install
(Engines With an Automatic
Belt Tensioner)
Removal Procedure
Start By:
a. Remove the alternator belt. Refer to Disassembly
and Assembly, Alternator Belt - Remove and
Install.
NOTICE
Illustration 125
g01763034
Typical example

component life.
6. Install a suitable lifting device to the ywheel

housing. The ywheel housing weighs
approximately 30 kg (66 lb).
7. Use the lifting device to align ywheel housing (1)
with Tooling (A). Install the ywheel housing to the
cylinder block.
8. Install bolts (2) and bolts (3) nger tight.
9. Remove Tooling (A). Install remaining bolts (3).
12. Use Tooling (B) to check the alignment of the
ywheel housing with the crankshaft. Refer
Flywheel Housing - Inspect.
End By:
a. Install the ywheel. Refer to Disassembly and
Assembly, Flywheel - Install.
Illustration 126
g01249049
1. Use a suitable tool in order to prevent the

crankshaft from rotating. Remove bolts (1).
2. Remove thrust block (2).
3. Carefully remove the assembly of the crankshaft
pulley from the crankshaft.
4. Follow Step 4.a through Step 4.b in order to
disassemble the crankshaft pulley.
b. Remove crankshaft pulley (4) from crankshaft
adapter (3).
RENR9525-01
71
NOTICE
component life.
1. Ensure that the crankshaft adapter, the pulley and
the thrust block are clean and free from damage.
Replace any components that are damaged.
Illustration 128
g01471632
4. Align the holes in the thrust block with the holes

in the crankshaft.
Note: Ensure chamfered Holes (X) in the thrust
block. Face toward the front of the engine.
5. Install thrust block (2) to the assembly of the
crankshaft pulley.
6. Install bolts (1) to thrust block (2).
crankshaft from rotating. Tighten the bolts to a
8. Repeat Step 7 in order to ensure correct torque.
Illustration 127
g01249049
2. If necessary, follow Step 2.a through Step 2.b in

order to assemble the crankshaft pulley.
a. Install crankshaft pulley (4) to crankshaft
adapter (3).
End By:
a. Install the alternator belt. Refer to Disassembly
Install.
i02933608
b. Install bolts (5) to the assembly of the

crankshaft pulley, and the crankshaft adapter.
The bolts should be evenly spaced.
c. Tighten the bolts to a torque of 78 Nm (58 lb ft).
3. Ensure that the front of the crankshaft is clean
and free from damage. Install the assembly of
crankshaft pulley (3) to the crankshaft.
Crankshaft Pulley - Remove

and Install
(Engines Without an Automatic
Belt Tensioner)
Removal Procedure
Start By:
a. Remove the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install.
72
RENR9525-01
NOTICE
component life.
g01471632
Illustration 131
1. Ensure that the crankshaft pulley and the thrust

block are clean and free from damage. Replace
any components that are damaged.
Illustration 129
g01255707

crankshaft from rotating. Remove bolts (1).
2. Remove thrust block (2).
3. Carefully remove crankshaft pulley (3) from the
crankshaft.
2. Ensure that the front of the crankshaft is clean and

free from damage. Install crankshaft pulley (3) to
the crankshaft.
3. Align the holes in the thrust block with the holes
in the crankshaft.
Note: Ensure that chamfered Holes (X) in the thrust
block face toward the front of the engine.
4. Install thrust block (2) to the crankshaft pulley.
5. Install bolts (1) to thrust block (2).

crankshaft from rotating. Tighten the bolts to a
7. Repeat Step 6 in order to ensure correct torque.
End By:
a. Install the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install.
i02933603
Illustration 130
g01255707
Crankshaft Front Seal Remove and Install

Removal Procedure
Table 34
Required Tools
Tool
Part Number
27610230
Part Description
Puller
Qty
1
RENR9525-01
73
Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
- Remove and Install.
NOTICE
component life.
Illustration 133
g01266453
Typical example
2. Assemble Tooling (B).

3. Align a new crankshaft front seal (1) to the front
housing.
g01266942
Illustration 132
1. Install the legs of Tooling (A) behind crankshaft

front seal (1). Install a suitable spacer (2) between
Tooling (A) and crankshaft (3). Use Tooling (A) in
order to pull the crankshaft front seal out of the
front housing.
Note: Do not damage the bore for the crankshaft
front seal in the front housing.
4. Use Tooling (B) to install crankshaft front seal (1).

Ensure that the front face of the seal is installed
to a depth of 9 0.2 mm (0.354 0.008 inch) into
the front housing.
5. Remove Tooling (B) from the crankshaft.
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, Crankshaft Pulley - Remove and
Install.
i02933635
Front Cover - Remove and

Install
Table 35
Required Tools
Tool
Part Number
Part Description
Qty
21825577
Threaded Bar
21825580
Anchor Plate
21825579
Sleeve
21825578
Pressure Plate
21825581
Adapter
NOTICE
Removal Procedure
Start By:
a. If the engine is equipped with a fan, remove the
fan. Refer to Disassembly and Assembly, Fan
b. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.

component life.
1. Ensure that the bore for the crankshaft front seal in
the front housing is clean and free from damage.
74
RENR9525-01
NOTICE
mandates.
NOTICE
Table 36
Required Tools
Tool
Part
Number
Part Description
Qty
Guide Bolt
M8 by 80 mm
NOTICE
component life.

component life.
Note: In order to remove the front cover, it is not
necessary to remove the crankshaft pulley or the
alternator.
Illustration 134
g01258462
Typical example
1. Remove bolts (3), (4) and (5). Identify the positions

of the different bolts.
2. Remove front cover (1) from the front housing.
3. Remove gasket (2) from front cover (1).
Illustration 135
g01471654
Typical example
1. Thoroughly clean the gasket surface of the front

housing.
2. If the original front cover is installed, follow Step
2.a and Step 2.b in order to install the gasket.
a. Thoroughly clean the gasket surface of the
front cover.
b. Install a new gasket (2) to front cover (1).
Engage Locators (Y) into the holes in the front
cover.
3. Install Tooling (A) into Holes (X) in the front
housing.
RENR9525-01
75
4. Use Tooling (A) in order to position the front cover

assembly onto the front housing.
5. Install bolts (3), (4) and (5) nger tight. Ensure
that the different bolts are installed in the correct
positions.
c. If the engine is equipped with an accessory drive,

remove the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.
d. Remove the front cover. Refer to Disassembly and
6. Loosely install the water pump assembly and

remove Tooling (A). Refer to Disassembly and
Assembly, Water Pump - Install for the correct
procedure.
e. Remove the valve mechanism cover. Refer to

7. Tighten bolts (3), (4) and (5) to a torque of 22 Nm

(16 lb ft).

8. Tighten the bolts for the water pump to a torque of

22 Nm (16 lb ft).
NOTICE
End By:

component life.
a. If the engine is equipped with a fan, install the

fan. Refer to Disassembly and Assembly, Fan
i02933652
Gear Group (Front) - Remove

and Install
NOTICE
mandates.
Removal Procedure
Table 37
Required Tools
Tool
Part Number
A(1)
21825576
27610291
27610289
Gear
27610212
Camshaft Timing Pin
27610211
A(2)
(1)
(2)
Part Description
Qty

the fuel injection pump timing is not lost during
the removal of the front gear group. Carefully
follow the procedure in order to remove the gear
group.

Start By:
a. If the engine is equipped with an air compressor,
remove the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.
b. If the engine is equipped with a vacuum pump,
remove the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.
76
RENR9525-01
g01471718
Illustration 138
Typical example
Illustration 136
g01471714
Typical example

gear (1) into the front housing. Use Tooling
(B) in order to lock the camshaft in the correct
position. Install Tooling (C) into Hole (Y) in the
front housing. Use Tooling (C) in order to lock the
crankshaft in the correct position.
during repairs.
4. Apply sufcient pressure to fuel injection pump

gear (7) in a counterclockwise direction in order
to remove the backlash. Lock the fuel injection
pump in this position. Refer to Disassembly and
Assembly, Fuel Pump Gear - Remove for the
correct procedure.
5. Mark gears (1), (6) and (7) in order to show
alignment. Refer to Illustration 138.
6. Remove fuel pump gear (7). Refer to Disassembly
and Assembly, Fuel Pump Gear - Remove for
the correct procedure.
7. Remove camshaft gear (1). Refer to Disassembly
and Assembly, Camshaft Gear - Remove and
Install.
8. Remove idler gear (6). Refer to Disassembly and
Assembly, Idler Gear - Remove.
Table 38
Required Tools
Illustration 137
g01471717
Typical example
3. Loosen nuts (4) on all rocker arms (5). Unscrew

adjusters (3) on all rocker arms (5) until all valves
are fully closed.
Note: Failure to ensure that ALL adjusters are fully
unscrewed can result in contact between the valves
and pistons.
Tool
Part
Number
27610212
Camshaft Timing Pin
27610286
21825617
Finger Clock
Part Description
Qty
NOTICE
component life.
RENR9525-01
77
Note: The fuel injection pump must remain locked

until the procedure instructs you to unlock the
fuel injection pump.
Illustration 141
g01488055
Typical example
4. Install camshaft gear (1). Loosely install bolt

(9) and washer (8). Refer to Disassembly and
Assembly, Camshaft Gear - Remove and Install
for more information.
gear (1) into the front housing.
Illustration 139
g01488044
Typical example
2. If necessary, install Tooling (C) into Hole (Y) in the

front housing. Use Tooling (C) in order to lock the
during repairs.
Illustration 142
3. Ensure that all of the components of the front gear

group are clean and free from wear of damage. If
necessary, replace any components that are worn
or damaged.
g01471736
Typical example
Illustration 143
g01471718

Illustration 140
g01471735
Typical example
78
6. Install idler gear (6). Ensure that the timing marks

on gears (1) and (6) are in alignment and that the
mesh of the gears is correct. Refer to Disassembly
and Assembly, Idler Gear - Install. Check the
end play of the idler gear. Refer to Specications,
Gear Group (Front) and refer to Disassembly
and Assembly, Idler Gear - Install for further
information.
7. Remove Tooling (B) and Tooling (C). Tighten bolt
(9) for the camshaft gear to a torque of 95 Nm
(70 lb ft). Check the end play of the camshaft
gear. Refer to Specications, Camshaft for more
information.
Install Tooling (B) through Hole (X) in camshaft
gear (1) into the front housing and install Tooling
(C) into Hole (Y) in the front housing.
8. Ensure that the fuel injection pump is locked in
the correct position. Refer to Disassembly and
Assembly, Fuel Injection Pump - Install.
9. Install fuel injection pump gear (7). Refer to
Disassembly and Assembly, Fuel Injection Pump
Gear - Install for the correct procedure. Ensure
that timing marks on gear (6) and gear (7) are in
alignment. See Illustration 143. Ensure that the
mesh of the gears is correct.
11. Use Tooling (D) in order to measure the backlash
for gears (1), (6) and (7). Ensure that the backlash
for the gears is within specied values. Refer to
Specications, Gear Group (Front) for further
information.
12. Lubricate each gear with clean engine oil.
13. Adjust the engine valve lash. Refer to Systems
End By:
RENR9525-01
e. If the engine is equipped with an accessory drive,

install the accessory drive. Refer to Disassembly
Install.
i03496189
Idler Gear - Remove

Removal Procedure (Early
Heavy-Duty Idler Gear)
Table 39
Required Tools
Tool
Part Number
Part Description
Qty
27610212
Camshaft Timing Pin
27610211
Start By:
Install.
Install.
Install.
d. Remove the fuel injection pump gear. Refer to
Gear - Remove.
b. Install the valve mechanism cover. Refer to


c. If the engine is equipped with an air compressor,

install the air compressor. Refer to Disassembly
Install.
NOTICE
d. If the engine is equipped with a vacuum pump,

install the vacuum pump. Refer to Disassembly
Install.

component life.
RENR9525-01
79
Note: The assembly of heavy-duty idler gear is not

serviceable. Do not disassemble the heavy-duty idler
gear.
1. Ensure that number one piston is at the top center
position on the compression stroke. Refer to
the Systems Operation, Testing and Adjusting,
g01832735
Illustration 146
Typical example
Illustration 144
g01473492
2. Ensure that Tooling (A) is installed into Hole (X) in

camshaft gear (1). Use Tooling (A) in order to lock
the camshaft in the correct position.
Note: Ensure that the gears are marked in order to
show alignment.
3. Ensure that Tooling (B) is installed in Hole (Y) in
the front housing. Use Tooling (B) in order to lock
g01832736
Illustration 147
Typical example
5. Remove bolts (6) from the assembly of heavy-duty

idler gear (5).
6. Remove the assembly of idler gear (5) from the
recess in the front housing.
Note: The idler gear must be tilted during removal.
i03496187
Idler Gear - Remove
Illustration 145
g01831356
Removal Procedure (Standard Idler

Gear)
Typical example
Table 40

are fully closed.
and pistons.
Required Tools
Tool
Part Number
Part Description
Qty
27610212
Camshaft Timing Pin
27610211
80
RENR9525-01

show alignment.
Start By:
Install.


Install.
Install.
Gear - Remove.
NOTICE
Illustration 149
g01831356
Typical example

are fully closed.
and pistons.

component life.
Illustration 150
g01473497
Typical example
5. Mark plate (5) in order to show orientation.

Note: Identication will ensure that the plate can be
installed in the original orientation.
6. Remove bolts (6).
Illustration 148
g01473492
7. Remove plate (5).

RENR9525-01
81

Gear - Remove.
g01473494
Illustration 151
Typical example
8. Remove the assembly of idler gear (8) and hub (7)

from the recess in the front housing.
NOTICE
component life.
Note: The assembly of heavy-duty idler gear is not
serviceable. Do not disassemble the heavy-duty idler
gear.
9. Remove hub (7) from idler gear (8).

i02933658
Idler Gear - Remove

Removal Procedure (Latest

Table 41
Required Tools
Tool
Part Number
Part Description
Qty
27610212
Camshaft Timing Pin
27610211
Bolt
M8x80mm
Illustration 152
g01473492
Start By:
Install.
Install.

show alignment.
the crankshaft in the correct Position.

Install.
82
RENR9525-01
6. Remove the assembly of idler gear (5) from the

recess in the front housing.
Illustration 153
g01831356
Typical example

are fully closed.
and pistons.
g01831473
Illustration 156
Typical example
7. If necessary, remove plate (7). Install Tooling (C)

into threaded Hole (Z) in order to remove plate (7).
i03496182
Idler Gear - Install
Illustration 154
g01832735
Installation Procedure (Heavy-Duty

Idler Gear)
Typical example
Table 42
Required Tools
Tool
Part Number
27610212
Camshaft Timing Pin
27610211
21825617
Finger Clock
Part Description
Qty
NOTICE
Illustration 155
g01831467
Typical example

component life.
5. Remove bolts (6) from the assembly of heavy-duty

idler gear (5).
RENR9525-01
83

Illustration 159
g01831467
Typical example
Illustration 157
g01473492

Illustration 158
6. Align the timing mark on idler gear (5) with the

timing mark on the camshaft gear. Refer to
Illustration 157. Install the assembly of idler gear
(5) into the recess in the timing case. Ensure that
the identication mark TOP is upward.
Note: The idler gear must be tilted during installation.
Ensure that the holes in assembly of the idler gear
are aligned with the holes in the cylinder block.
7. Install bolts (6). Tighten bolts (6) to a torque of
44 Nm (32 lb ft).
g01832735
Typical example
Illustration 160
g01832813
Checking end play by using a dial indicator group
4. Clean the assembly of idler gear (5) and inspect

the assembly of the idler gear for wear or damage.
Refer to Specications, Gear Group (Front)
for more information. If necessary, replace the
assembly of the idler gear.
5. Lubricate the bearings in the assembly of idler
gear (5) with clean engine oil.
8. Use Tooling (C) in order to check the end play

of the idler gear. Refer to Specications, Gear
Group (Front) for more information.
9. Use Tooling (C) in order to check the backlash
between the idler gear and the camshaft gear.
Refer to Specications, Gear Group (Front) for
more information.
between the idler gear and the crankshaft gear.
more information.
84
RENR9525-01
11. Lightly lubricate all of the gears with clean engine

oil.

End By:
a. Install the fuel injection pump gear. Refer to
Gear - Install.
b. If the engine is equipped with an air compressor,
Install.
c. If the engine is equipped with a vacuum pump,
Install.
d. If the engine is equipped with an accessory drive,
Install.
e. Install the valve mechanism cover. Refer to
Illustration 161
g01473492

i03496180

Installation Procedure (Standard
Idler Gear)
Table 43
Required Tools
Tool
Part Number
27610212
Camshaft Timing Pin
27610211
21825617
Finger Clock
Part Description
Illustration 162
Qty
NOTICE
component life.
g01832693
Typical example
4. Clean idler gear (8) and inspect the idler gear for
wear or damage. Refer to Specications, Gear
Group (Front) for more information. If necessary,
replace the idler gear.
5. Clean hub (7) and inspect the hub for wear or
damage. Refer to Specications, Gear Group
(Front) for more information. If necessary, replace
the hub.
6. Lubricate hub (7) with clean engine oil. Slide the
hub into idler gear (8). Ensure that the timing
marks are toward the front of the idler gear.
RENR9525-01
85

more information.
more information.
oil.
Illustration 163
g01832695

Typical example
End By:
timing mark on the camshaft gear. Refer to the
(8) and hub (7) into the recess in the timing case.
Ensure that oil Hole (Z) is to the top of the hub.

Gear - Install.

Ensure that the holes in the hub are aligned with the
holes in the cylinder block.

Install.
8. Clean plate (5) and inspect the plate for wear or

damage. If necessary, replace the plate.
9. Lubricate plate (5) with clean engine oil. A used
plate should be installed in the original orientation.
If a new plate is installed, ensure that the holes
in plate (5) are aligned with the holes in hub (7).
Install plate (5) to hub (7).
44 Nm (32 lb ft).

Install.
Install.
i02933657

Installation Procedure (Latest
Table 44
Illustration 164
Required Tools
g01269936
Checking end play by using a set of feeler gauge's
11. Use a set of feeler gauge's in order to check the

end play of the idler gear. Refer to Specications,
Gear Group (Front) for more information.
Tool
Part Number
27610212
Camshaft Timing Pin
27610211
21825617
Finger Clock
Part Description
Qty
86
RENR9525-01
Note: Ensure that the identication mark TOP is

upward.
NOTICE
component life.
center Position on the compression stroke. Refer
Illustration 167
g01832735
Typical example
5. Clean the assembly of idler gear (5) and inspect

the assembly of the idler gear for wear or damage.
Refer to Specications, Gear Group (Front)
for more information. If necessary, replace the
assembly of the idler gear.
Illustration 165
g01473492
6. Lubricate the bearings in the assembly of idler

gear (5) with clean engine oil.

the cylinder block. Use Tooling (B) in order to lock
Illustration 168
g01831467
Typical example

timing mark on the camshaft gear. Refer to
(5) into the recess in the timing case. Ensure that
the identication mark TOP is upward.
Ensure that the holes in the assembly of the idler
gear are aligned with the holes in the cylinder block.
44 Nm (32 lb ft).
Illustration 166
g01831473
Typical example
4. Install plate (2) into the recess in the front housing.
RENR9525-01
87
i02933656
Housing (Front) - Remove

Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
Illustration 169
g01832813
Checking end play by using a dial indicator group
9. Use Tooling (D) in order to check the end play

of idler gear (5). Refer to Specications, Gear
Group (Front) for more information.
10. Use Tooling (D) in order to check the backlash
more information.
11. Use Tooling (D) in order to check the backlash
more information.
oil.
End By:
Gear - Install.
Install.
Install.
Install.
b. Remove the alternator. Refer to Disassembly and

Assembly, Alternator - Remove.
c. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
d. Remove the engine oil pan. Refer to Disassembly
Install.
e. Remove the timing gears. Refer to Disassembly
and Assembly, Gear Group (Front) - Remove
and Install.
f. Remove the fuel injection pump. Refer to
- Remove.
NOTICE
component life.
NOTICE
mandates.
1. Ensure that the coolant is drained into a suitable
container for storage or disposal. Refer to
procedure.

88
Illustration 170
RENR9525-01
g01475066
Typical example
2. Remove bolts (1) that secure bypass tube (2)

to front housing (3). Remove bypass tube (2).
Remove O-ring seal (4) and O-ring seal (5) from
bypass tube (2).
Note: Note the position of any brackets that are
secured by the bolts.
Illustration 172
g01475067
Typical example
4. Remove bolts (8), (9) and (10) from front housing

(3).
Note: The bolts are three different lengths. Note the
positions of the different bolts.
5. Remove front housing (3) from the cylinder block.
Illustration 171
g01475068
Typical example
Illustration 173
3. If the engine is equipped with a heavy duty idle

gear. Remove plate (6). Refer to Disassembly and
Assembly, Idler Gear - Remove for the correct
procedure.
g01475069
Typical example
7. Remove thrust washer (11) from the cylinder

block.
RENR9525-01
89
i02933655
Housing (Front) - Install

Table 45
Required Tools
Tool
Part
Number
21820117
POWERPART
Threadlock and
Nutlock
Guide Stud
(M8 by 80 mm)
27610216
Alignment Tool
Bolts
(M10 by 50 mm)
Straight Edge
21820221
POWERPART
Rubber Grease
Part Description
Qty
Illustration 174
g01475069
Typical example
4. Install thrust washer (11) into the recess in

the cylinder block. Refer to Disassembly
and Assembly, Camshaft - Install for more
information.
NOTICE
component life.
1. Ensure that the front housing is clean and free
from damage. If necessary, replace the front
housing.
If necessary, install blanking plugs to a new front
housing. Use Tooling (A) to seal all D-plugs.
2. Check the condition of the crankshaft front seal. If
the front seal is damaged, remove the front seal
from the front housing.
Illustration 175
g01475134
Typical example
3. Clean the surfaces of the cylinder block.
Illustration 176
g01269947
Typical example
90
RENR9525-01
5. Install Tooling (B) to the cylinder block. Refer to

Illustration 175.
6. Install Tooling (C) to the cylinder block.
7. Align a new gasket (6) with Tooling (B) and Tooling
(C). Install the gasket to the cylinder block.
Note: Ensure that Tabs (X) on the gasket are
engaged in Holes (Y) in the cylinder block.
8. Install the front housing over Tooling (B) and over
Tooling (C) onto the cylinder block.
Illustration 178
g01269949
Tightening sequence for the front housing
13. Tighten bolts (7), (8) and (9) to a torque of 28 Nm

(20 lb ft). Tighten the bolts in the sequence that is
shown in Illustration 178.
Note: Ensure that the housing and the cylinder block
are correctly aligned.
14. Remove Tooling (C) from the cylinder block.
Illustration 177
g01269948
(7) M8 by 20 mm
(8) M8 by 35 mm
(9) M8 by 25 mm
15. If necessary, install a new crankshaft front seal.

Front Seal - Remove and Install.
9. Install bolts (9) to front housing (3) nger tight.

11. Loosely install bolt (7) and bolt (8). Refer to
Illustration 177 for the correct position of the bolts.
12. Align the bottom face of front housing (3) to the
lower machined face of the cylinder block. Use
Tooling (D) and a feeler gauge in order to check
the alignment between the front housing and the
cylinder block. Refer to Illustration 176. Refer to
Specications, Front Housing and Covers for
Illustration 179
g01475068
Typical example
RENR9525-01
91
16. If the engine is equipped with a heavy duty idle

gear. Install plate (6). Refer to Disassembly and
Assembly, Idler Gear - Install for the correct
procedure.
i02933583
Accessory Drive - Remove

Removal Procedure
NOTICE
component life.
Illustration 180
g01475066
Typical example
17. Install new O-ring seal (4) and O-ring seal (5)
to bypass tube (2). Use Tooling (E) in order to
lubricate O-ring seal (5). Install bypass tube (2) to
front housing (3). Install bolts (1). Tighten the bolts
NOTICE
mandates.
Note: Ensure that any brackets that are secured by

the bolts are installed in the correct location.
procedure.
End By:
a. Install the fuel injection pump. Refer to
- Install.
b. Install the timing gears. Refer to Disassembly and
Assembly, Gear Group (Front) - Remove and
Install.
c. Install the engine oil pan. Refer to Disassembly
Install.
Illustration 181
d. Install the crankshaft pulley. Refer to Disassembly

and Assembly, Crankshaft Pulley - Remove and
Install.
1. Remove allen head screw (1) from accessory

drive housing (4). Remove allen head screws (2)
from accessory drive housing (4).
e. Install the alternator. Refer to Disassembly and

Assembly, Alternator - Install.
2. Remove accessory drive housing (4) from front

housing (3).
f. Install the fan. Refer to Disassembly and

3. Remove O-ring seal (5) (not shown) from

accessory drive housing (4).
g01441026
Typical example
92
RENR9525-01
i02933581
Accessory Drive - Disassemble
2. Place accessory drive housing (4) onto a suitable

support. Press the assembly of gear (7), bearing
(6) and bearing (8) out of accessory drive housing
(4).
3. Use a Tooling (A) in order to remove bearing (6)
and bearing (8) from gear (7).
Disassembly Procedure
Table 46
i02933580
Required Tools
Tool
Part Number
Part Description
Qty
Bearing Puller
Puller
Crossblock
Puller Leg
Accessory Drive - Assemble

Assembly Procedure
Table 47
Required Tools
NOTICE
Tool
Part Number
21820603

component life.
NOTICE
Part Description
POWERPART
Retainer
Qty
1
NOTICE
component life.

mandates.
Illustration 183
g01440577
Typical example
Illustration 182
g01440573
Typical example
1. Inspect the condition of the teeth and the splines

of gear (7) for wear or damage. Inspect bearing
(6) and bearing (8). Inspect circlip (9), and front
housing (4) for wear or damage. Replace any
components that are worn or damaged.
1. Remove circlip (9) from accessory drive housing

(4).
RENR9525-01
93
2. Apply a small continuous bead of Tooling (B) to

inner Surface (X) of bearing (6). Place the gear
shaft on a suitable support. Press on the inner
race of bearing (6) until bearing (6) is against the
shoulder of gear (7). Remove any excess sealant.
3. Apply a small continuous bead of Tooling (B)
to inner Surface (Z) of bearing (8). Place the
inner race of bearing (8) onto a suitable support.
Press the shaft of gear (7) onto bearing (8) until
the shoulder of the gear is against the bearing.
Remove any excess sealant.
4. Apply a small continuous bead of Tooling (B) to
outer Surface (Y) of bearing (6) and bearing (8).
Place accessory drive housing (4) on a suitable
support. Press the assembly of the gear into the
accessory drive housing. Ensure that bearing (6)
is against the front face of the recess in accessory
drive housing (4). Remove any excess sealant.
5. Install circlip (9) into the groove in accessory drive
housing (4). Ensure that circlip (9) is correctly
positioned in the groove.
Illustration 184
g01441026
Typical example
i02933582
Accessory Drive - Install

Table 48
Required Tools
Tool
Part Number
Part Description
Qty
21820221
POWERPART
Rubber Lubricant
21820117
POWERPART
NOTICE
Illustration 185
g01444555
Sequence for tightening accessory drive

component life.
1. Inspect the bore in front housing (3) for damage.

If necessary, replace the front housing. Refer to
Disassembly and Assembly, Housing (Front)
- Remove and Disassembly and Assembly,
Housing (Front) - Install.
2. Lightly lubricate a new O-ring seal (5) (not shown)
with Tooling (C). Install the O-ring seal (not shown)
into the groove in accessory drive housing (4).
3. Lightly lubricate all bearings, and all gears with
clean engine lubricating oil. Install the assembly of
the accessory drive to the front housing. Ensure
that the ange on the accessory drive housing is
ush with the front housing.
94
RENR9525-01
4. Apply Tooling (D) to allen head screws (1) and

allen head screw (2).
5. Install allen head screws (1) and allen head screw
(2) to accessory drive housing (4).
6. Tighten allen head screws (1) to a torque of
22 Nm (16 lb ft).
Tighten allen head screw (2) to a torque of 44 Nm
(32 lb ft). Tighten allen head screws (1) and (2) in
the sequence that is shown in Illustration 185.
7. Ensure that there is tactile backlash between the
idler gear and the accessory drive gear.
i02933599
Crankcase Breather - Remove

and Install
(Filtered Breather)
Removal Procedure
NOTICE
Illustration 186
g01475258
Typical example
1. Remove canister (8). Refer to Operation and

Maintenance Manual, Crankcase Breather
(Canister) - Replace.
2. Loosen clamp (6) and remove hose (7).

mandates.
NOTICE
component life.
3. Release spring clamps (2) in order to remove hose

(3). Remove the hose from connection (1) on the
valve mechanism cover and from lter base (4).
4. Remove bolts (5) and remove lter base (4).
Note: If a spacer is installed between the lter base
and the engine, remove the spacer.
Illustration 187
g01903114
RENR9525-01
95
5. If necessary, use a suitable tool in order to remove

connection (9) from lter base (4).
Table 49
Required Tools
Tool
Part Number
Part Description
Qty
21820118
Thread Lock Compound
NOTICE
component life.
1. Ensure that all components of the crankcase
breather are clean and free from damage. Replace
Illustration 189
g01475258
Typical example
3. Install bolts (5) to lter base (4).

Note: If spacers are installed, position the spacers
over the bolts.
Illustration 188
g01903114
4. Install the assembly of the lter base to the engine.

2. If necessary, install connection (9) to lter base

(4). Follow Step 2.a through Step 2.c in order to
install connection (9) to lter base (4).
a. Apply a bead of Tooling (A) to the threads of
connection (9).
6. Install spring clamps (2) to hose (3). Install hose

(3) to connection (1) on the valve mechanism
cover and to lter base (4).
Note: Ensure that the spring clamps are correctly
positioned in order to secure the hose.
b. Install connection (9) to lter base (4).

c. Tighten connection (9) to a torque of 50 Nm
(37 lb ft).
7. Install clamp (6) to hose (7). Install hose (7) to

lter base (4). Tighten the clamp securely.
8. Install a new canister (8) to lter base (4). Refer to
Operation and Maintenance Manual, Crankcase
Breather (Canister) - Replace.
96
RENR9525-01
i02933600
Crankcase Breather - Remove

and Install
(Unltered Breather)
Removal Procedure
NOTICE
component life.
Illustration 191
g01475234
Typical example
2. Connect hose (3) to connection (1) on the valve

mechanism cover. Tighten clamp (2). Install hose
(3) into clip (4).
i02933677
Valve Mechanism Cover Remove and Install

Removal Procedure
Illustration 190
g01475234
Start By:
Typical example
1. Loosen clamp (2) and remove hose (3) from

connection (1) on the valve mechanism cover.
Withdraw hose (3) from clip (4) and remove the
hose.
a. Disconnect the crankcase breather or remove the

crankcase breather. Refer to Disassembly and
Assembly, Crankcase Breather - Remove and
Install.
NOTICE
NOTICE

component life.

component life.
1. Ensure that all components of the crankcase
breather are clean and free from damage. Replace
Illustration 192
g01788614
RENR9525-01
97
1. If the valve mechanism cover is equipped with a

heat shield, remove bolts (1) and washers (3) from
heat shield (2).
Note: The washers are two different sizes. Note the
position of the washers for installation purposes.
2. Remove heat shield (2).
Illustration 194
g01788720
Typical example
2. Install a new gasket (7) to valve mechanism cover

(6).
Note: Ensure that the gasket is fully seated into the
groove of the valve mechanism cover.
Illustration 193
g01788720
Typical example
3. Remove bolts (4) and bolts (5) from valve

mechanism cover (6).
4. Remove valve mechanism cover (6) from the
5. Remove gasket (7) from valve mechanism cover
(6).
g01788815
NOTICE
Illustration 195

component life.
3. Ensure that harness assemblies (9) are not in

contact with the rocker arms or in contact with
the valve mechanism cover base. Position valve
mechanism cover (6) onto valve mechanism cover
base (8). Ensure that harness assemblies (9) are
not trapped during the assembly procedure. Install
bolts (4) and bolts (5).
1. Thoroughly clean the valve mechanism cover.

Clean the faces of the valve mechanism cover
base.
Typical example
98
RENR9525-01
i02933678
Valve Mechanism Cover Base Remove and Install

Removal Procedure
Table 50
Required Tools
Illustration 196
g01245162
Tightening sequence for the valve mechanism cover
Tool
Part Number
Part Description
Circlip Pliers
Qty
1
Start By:
4. Tighten bolts (4) and bolts (5) in the numerical

sequence that is shown in Illustration 196. Tighten
the bolts to a torque of 6 Nm (53 lb in).

b. Remove the fuel injection lines. Refer to
- Remove.
NOTICE
component life.
Illustration 197
g01788614
5. If necessary, position heat shield (2) onto the

valve mechanism cover.
NOTICE
unit injectors.
6. Install bolts (1) and washers (3). Tighten the bolts

to a torque of 9 Nm (80 lb in).
End By:
a. Connect the crankcase breather or install the
crankcase breather. Refer to Disassembly and
Assembly, Crankcase Breather - Remove and
Install.
Illustration 198
g01476212
Typical example
RENR9525-01
99
1. Make a temporary identication mark on

connections (1).
from electronic unit injectors (2).
3. Disconnect plugs (7) from harness assemblies (4).
4. If necessary, follow Step 4.a through Step 4.e
in order to remove harness assemblies (4) from
valve mechanism cover base (6).
a. Cut cable strap (3).
b. Use Tooling (A) to remove circlip (5).
g01245190
Illustration 200
c. From the outside of valve mechanism cover

base (6), push harness assembly (4) inward.
Withdraw the harness assembly from valve
mechanism cover base (6).
Sequence for loosening captive bolts in valve mechanism
d. Remove O-ring seal (8) from harness assembly

(4).
5. Progressively loosen the captive bolts that secure

the valve mechanism cover base in reverse
numerical order. Refer to Illustration 200. This will
help prevent distortion of the valve mechanism
cover base.
e. Repeat Step 4.a through Step 4.d in order to

remove the remaining harness assembly.
Note: The captive bolts cannot be removed from the

6. Remove the valve mechanism cover base from
the cylinder head.
7. Remove gasket (9) from the valve mechanism
cover base .
Table 51
Required Tools
Illustration 199
Typical example
g01245186
Tool
Part Number
Part Description
Qty
Circlip Pliers
21820221
POWERPART
Rubber Grease
27610296
Torque wrench
27610349
Alignment Pins
NOTICE
component life.
NOTICE
unit injectors.
1. Clean the valve mechanism cover base. Ensure
that the gasket surfaces are free from damage.
100
Illustration 201
RENR9525-01
g01245186
Typical example
Illustration 203
g01476212
Typical example
7. If necessary, install the harness assemblies for the

electronic unit injectors. Follow Step 7.a through
Step 7.e in order to install the harness assemblies
to the electronic unit injectors.
a. Ensure that harness assembly (4) and the bore
in valve mechanism cover base (6) are clean
components.
b. Use Tooling (B) to lubricate a new O-ring
seal (8). Install O-ring seal (8) onto harness
assembly (4).
g01272185
Tightening sequence for the valve mechanism cover base
c. From the inside of valve mechanism cover

base (6), push harness assembly (4) into the
2. Install gasket (9) to valve mechanism cover base

(6). Ensure that the gasket is seated correctly in
the groove in the valve mechanism cover base.
d. Use Tooling (A) to install circlip (5).
Illustration 202
3. Position valve mechanism cover base (6) on the

cylinder head.
e. Repeat Step 7.a through Step 7.e for the

remaining harness assembly.
4. Install Tooling (D) into the valve mechanism cover

base in Positions (X).
8. Use a deep socket to connect harness (4) to

electronic unit injectors (2). Use Tooling (C) to
tighten connectors (1) to a torque of 2.4 Nm
(21 lb in).
5. Progressively tighten the captive bolts that secure

the valve mechanism cover base. Tighten the
captive bolts to a torque of 9 Nm (79 lb in) in the
9. If necessary, install new cable strap (3) to harness

assemblies (4).
6. Remove Tooling (D).
Note: Ensure that the cable straps conform to the

Perkins specication.
10. Connect plugs (7) to harness assemblies (4).
RENR9525-01
101
End By:
a. Install new fuel injection lines. Refer to
- Install.
i02933672
Rocker Shaft and Pushrod Remove

Removal Procedure
Table 52
Illustration 205
Required Tools
Tool
Part Number
Part Description
E12 Torx Socket
Qty
1
Start By:
g01792634
Typical example
1. Use Tooling (A) in order to progressively loosen

torx screws (1). Begin at the ends of the rocker
shaft assembly and work toward the center.

Note: To avoid distortion of the rocker shaft assembly,

each torx screw should be loosened by a quarter of a
turn at one time. Repeat the procedure until all torx
screws are loosened.
NOTICE
2. Remove torx screws (1) from rocker shaft

assembly (2).

component life.
3. Remove rocker shaft assembly (2) from the

cylinder head.
4. Make a temporary mark on pushrods (3) in order
to show the location. Remove the pushrods from
the cylinder head.
Note: Identication will ensure that the pushrods
can be reinstalled in the original positions. Do not
interchange the positions of used pushrods.
5. Make a temporary mark on valve bridges (4) in
order to show the location and the orientation.
Remove the valve bridges from the cylinder head.
If the valve bridges are equipped with shrouds (5),
ensure that the shrouds are removed from the
cylinder head.
Illustration 204
g01476297
Note: Identication will ensure that the valve bridges

can be reinstalled in the original location and the
original orientation. Do not interchange the location
or the orientation of used valve bridges.
102
RENR9525-01
i02933670
Rocker Shaft - Disassemble

Start By:
Pushrod - Remove.

NOTICE
component life.
1. Make an identication mark on each rocker arm
assembly in order to show the location.
Note: The components must be reinstalled in the
original location. Do not interchange components.
Illustration 206
g01476312
Typical example
2. Remove pedestals (1) from rocker shaft (5). Do

not remove dowels (2) from the pedestals.
3. Remove rocker arm assembly (4) for the exhaust
valve from rocker shaft (5). Remove rocker arm
assembly (3) for the inlet valve from rocker shaft
(5). Begin at the rear of the rocker shaft assembly.
Note: The rocker arm assembly for the inlet valve is
longer than the rocker arm assembly for the exhaust
valve.
4. Remove spring (6) from rocker shaft (5).
5. Repeat Step 3 and Step 4 in order to remove the
remaining rocker arms from rocker shaft (5).
Illustration 207
g01181801
RENR9525-01
103
6. If necessary, remove retaining clip (7) and remove

spring (8) from the front end of rocker shaft (5).
7. If necessary, remove nuts (9) and adjusters
(10) from the rocker arms. Make a temporary
identication mark on each adjuster in order to
show the location.
Note: The components must be reinstalled in the
original location. Do not interchange components.
i02933669
Rocker Shaft - Assemble

Assembly Procedure

Illustration 208
g01476312
Typical example
NOTICE
component life.
from wear or damage. Refer to Specications,
Rocker Shaft for more information. If necessary,
replace any components that are worn or
damaged.
Illustration 209
g01270008
2. If necessary, install nuts (9) and adjusters (10) to

rocker arm assemblies (3) and (4). If the original
adjusters are reused, ensure that the adjusters
are installed in the original positions.
3. Install retaining clip (7) and spring (8) to the front
end of rocker shaft (5).
4. Lubricate the bores of rocker arm assemblies (3)
and (4) and rocker shaft (5) with clean engine oil.
104
RENR9525-01
5. Place the rocker shaft in the inverted position with

the counterbores for the holes downward. Install
rocker arm assembly (3) for number 1 cylinder
inlet valves to the rocker shaft. Install rocker arm
assembly (4) for number 1 cylinder exhaust valves
to rocker shaft (5).
Note: The rocker arms for the inlet valves are
longer than the rocker arms for the exhaust valves.
Install rocker arms in the inverted position. Used
components should be installed in the original
location.
6. Ensure that dowel (2) is correctly seated in
pedestal (1). Align the dowel with the appropriate
hole in rocker shaft (5). Install the pedestal to the
rocker shaft.
7. Install spring (6) to rocker shaft (5).
8. Repeat Step 5 through Step 7 in order to assemble
the remaining components to rocker shaft (5).
Illustration 210
g01794035
g01794053
End By:
a. Install the rocker shaft assembly. Refer to
Pushrod - Install.
i02933671
Rocker Shaft and Pushrod Install

Table 53
Required Tools
Tool
Part Number
27610298
Part Description
Qty
E10 Torx Socket
Illustration 211
Feeler Gauge
The correct location of valve bridges on valve stems is shown. The

electronic unit injector is not shown for clarity.
NOTICE
component life.
1. Clean the valve bridges. Inspect the valve bridges
for wear or damage. Replace any valve bridges
that are worn or damaged.
NOTICE
2. Lubricate valve bridges (4) with clean engine oil.
Install the valve bridges to the cylinder head.
the valve bridges are equipped with shrouds (5),
RENR9525-01
105
Note: Install used valve bridges in the original

location and in the original orientation. Ensure that the
valve bridges are correctly seated on the valves. New
valve bridges may be installed in either orientation.
4. Clean pushrods (3). Inspect the pushrods for wear
or damage. Replace any pushrods that are worn
or damaged.
Note: To avoid distortion of rocker shaft assembly

(2), tighten the torx screws in the center rst. Work
toward the outside of the rocker shaft assembly.
Tighten the torx screws to a torque of 35 Nm
(26 lb ft).
5. Apply clean engine lubricating oil to both ends of

pushrods (3). Install the pushrods to the engine
with the cup upward.
Note: Ensure that the pushrods are installed in the
original location and that the ball end of each pushrod
is correctly seated in the valve lifters.
Illustration 214
g01259267
Typical example
9. Use Tooling (B) in order to check the valve lash. If

necessary, adjust the valve lash. Refer to Systems
Lash - Inspect/Adjust for the correct procedure.
End By:
Illustration 212
g01476297
6. Ensure that the rocker shaft assembly is clean

and free from wear or damage. Install torx screws
(1) in the rocker shaft.
a. Install the valve mechanism cover. Refer to

i02933613
Cylinder Head - Remove

Removal Procedure
Start By:
a. Remove the exhaust manifold. Refer to
Disassembly and Assembly, Exhaust Manifold
Illustration 213
g01794061
7. Position rocker shaft assembly (2) onto the

cylinder head. Retaining clip (7) should face the
front of the engine.
Note: Ensure that adjustment screws (6) are properly
seated in the ends of pushrods (3).
8. Use Tooling (A) to gradually tighten torx screws
(1).
b. Remove the fuel manifold. Refer to Disassembly

and Assembly, Fuel Manifold (Rail) - Remove
and Install.
c. Remove the mounting bracket for the electronic
Assembly, ECM Mounting Bracket- Remove and
Install.
d. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, Electronic Unit
Injector - Remove.
106
RENR9525-01
e. Remove the valve mechanism cover base. Refer

to Disassembly and Assembly, Valve Mechanism
Cover Base - Remove and Install.
f. Remove the glow plugs. Refer to Disassembly
and Assembly, Glow Plugs - Remove and Install.
NOTICE
component life.
NOTICE
Illustration 215

mandates.
the system.
1. If the alternator bracket is mounted on the cylinder
head, remove the alternator. Refer to Disassembly
and Assembly, Alternator - Remove.
2. If the fuel priming pump and the primary fuel lter
are mounted on the cylinder head, remove the fuel
priming pump and the primary fuel lter. Refer to
Disassembly and Assembly, Fuel Priming Pump
draining procedure.
g01245537
Typical example
4. Disconnect the upper radiator hose from water

temperature regulator housing (1).
5. If necessary, remove the air hose from the inlet
connection.
6. Follow Step 6.a and Step 6.b in order to disconnect
harness assembly (4) from coolant temperature
sensor (2).
a. Slide the locking tab into the unlocked position.
b. Disconnect harness assembly (4) from coolant
temperature sensor (2).
7. If necessary, follow Step 7.a and Step 7.b in order
to disconnect harness assembly (4) from boost
pressure sensor (3).
b. Disconnect harness assembly (4) from boost
RENR9525-01
Illustration 216
107
g01249835
Typical example
8. Follow Step 8.a and Step 8.b in order to disconnect

harness assembly (4) from inlet air temperature
sensor (5).
b. Disconnect harness assembly (4) from inlet air
9. Remove all cable straps that secure harness
assembly (4) to the cylinder head. The harness
assembly should be positioned in order to avoid
causing an obstruction during the removal of the
cylinder head.
Illustration 218
g01249479
Typical example
11. If the engine is equipped with a wastegate

solenoid, remove harness assembly (9) from tube
assembly (8). Remove the bolts for tube clip (10)
and tube clip (11). Remove tube assembly (8)
from the wastegate solenoid and from the cylinder
head.
Illustration 219
g01476537
Typical example
12. Remove bolts (12). Note the position of any

brackets that are secured by the bolts. Remove
bypass tube (13) from the cylinder head. Remove
O-ring seals (14) and (15) from the bypass tube.
Illustration 217
g01249474
Typical example
10. Remove tube assembly (6) from the cylinder head

and from transfer pump (7).
108
Illustration 220
RENR9525-01
g01245538
Illustration 222
g01763153
Typical example
17. Remove cylinder head gasket (19).

18. Note the position of dowels (18) in the cylinder
block. Do not remove the dowels unless the
dowels are damaged.
Illustration 221
g01250785
Sequence for loosening the bolts for the cylinder head
13. Gradually loosen bolts (16) in the reverse

numerical order to the sequence that is shown in
Illustration 221.
Note: Follow the correct sequence in order to help
prevent distortion of the cylinder head.
14. Remove bolts (16) from cylinder head (17).
15. Attach a suitable lifting device to cylinder head
(17). Support the weight of the cylinder head. The
weight of the cylinder head is approximately 56 kg
(124 lb).
16. Use the suitable lifting device to carefully lift
cylinder head (17) off the cylinder block.
Note: Do not use a lever to separate the cylinder
head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head
during the removal procedure.
Illustration 223
g01763173
Typical example
19. If necessary, remove screws (20) and remove

mounting bracket (21) from the cylinder head.
20. If necessary, remove the water temperature
regulator from the cylinder head. Refer to
Disassembly and Assembly, Water Temperature
Regulator - Remove and Install.
21. If necessary, remove the electronic sensors
from the cylinder head. Refer to Disassembly
and Assembly, Coolant Temperature Sensor Remove and Install. Refer to Disassembly and
Assembly, Air Temperature Sensor - Remove
and Install. Refer to Disassembly and Assembly,
Boost Pressure Sensor - Remove and Install.
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
RENR9525-01
109
Cylinder Head - Install
5. Align cylinder head gasket (19) with Tooling (A)

and with dowels (18). Install the cylinder head
gasket onto the cylinder block.
6. Use a suitable lifting device to lift the cylinder head.

The weight of the cylinder head is approximately
56 kg (124 lb).
i02933612
7. Use Tooling (A) to align cylinder head (17) with

the cylinder block. Install the cylinder head to the
cylinder block.
Table 54
Required Tools
Tool
Part Number
Part Description
Qty
Guide Bolt
M16 by 115mm
Straight Edge
21825607
Angle gauge
2180221
POWERPART
Rubber Grease
Note: Ensure that the cylinder head is correctly

positioned onto dowels (18).
NOTICE
component life.
1. Thoroughly clean the gasket surfaces of the
cylinder head and the cylinder block. Do not
damage the gasket surfaces of the cylinder head
or the cylinder block. Ensure that no debris enters
the cylinder bores, the coolant passages, or the
lubricant passages.
Illustration 225
g01250784
8. Clean bolts (16). Follow Step 8.a and Step 8.b for
the procedure to inspect the bolts.
a. Check the length of the bolts.
2. Inspect the gasket surface of the cylinder head

for distortion. Refer to Specications, Cylinder
Head for more information. If the gasket surface
of the cylinder head is distorted beyond maximum
permitted limits, replace the cylinder head.
b. Use Tooling (B) in order to check the threads of

the bolts. Refer to Illustration 225. Replace any
bolts that show visual reduction in the diameter
of the thread over length (Y).
9. Lubricate the threads and the shoulder of bolts
(16) with clean engine oil.
Illustration 224
g01763193
3. Inspect dowels (18) for damage. If necessary,

replace the dowels in the cylinder block.
4. Install Tooling (A) to the cylinder block. Refer to
Illustration 224.
Illustration 226
g01245538
110
Illustration 227
RENR9525-01
g01476553
Illustration 229
g01249479
Sequence for tightening the bolts for the cylinder head
Typical example
11. Install bolts (16) to cylinder head (17).
16. If the engine is equipped with a wastegate

solenoid, install tube assembly (9) to the
wastegate solenoid and to the cylinder head.
Install the bolts for tube clip (10) and tube clip (11).
Tighten M8 bolts to a torque of 22 Nm (16 lb ft).
Secure harness assembly (9) to tube assembly
(8).
12. Tighten bolts (16) to a torque of 50 Nm (37 lb ft)

13. Tighten bolts (16) to a torque of 100 Nm (74 lb ft)
14. Use Tooling (C) to turn bolts (16) through an
additional 225 degrees. Turn bolts (16) in the
Illustration 228
g01476537
Typical example
15. Install new O-ring seal (14) and O-ring seal (15)
to bypass tube (13). Use Tooling (D) in order to
lubricate O-ring seal (14). Install the bypass tube
to the cylinder head. Install bolts (12). Tighten the
Note: Ensure that any brackets that are secured by
the bolts are installed in the correct position.
Illustration 230
g01249474
Typical example

install tube assembly (6) for the fuel return.
a. Install the banjo bolts and new sealing washers
RENR9525-01
111
b. Install tube assembly (6) to the cylinder head

and to transfer pump (7).
c. Tighten the banjo bolts to a torque of 21 Nm
(15 lb ft).
18. If necessary, install the electronic sensors to
the cylinder head. Refer to Disassembly and
Assembly, Coolant Temperature Sensor Remove and Install. Refer to Disassembly and
Assembly, Air Temperature Sensor - Remove
and Install. Refer to Disassembly and Assembly,
Boost Pressure Sensor - Remove and Install.
Illustration 233
g01245537
Typical example
Illustration 231
g01763173
Typical example
19. If necessary, install mounting bracket (21) and

install screws (20) to the cylinder head. Tighten
the screws to a torque of 22 Nm (16 lb ft).
21. If necessary, install water temperature regulator

housing (1) to the cylinder head. Refer to
Disassembly and Assembly, Water Temperature
Regulator Housing - Remove and Install.
22. Connect the upper radiator hose to water
temperature regulator housing (1). Tighten the
hose clip securely.
23. Follow Step 23.a and Step 23.b in order to
connect harness assembly (4) to boost pressure
sensor (3).
a. Connect harness assembly (4) to boost
b. Slide the locking tab into the locked position.
24. Follow Step 24.a and Step 24.b in order
to connect harness assembly (4) to coolant
a. Connect harness assembly (4) to coolant
Illustration 232
g01249835
Typical example
20. Follow Step 20.a and Step 20.b in order

to connect harness assembly (4) to inlet air
a. Connect harness assembly (4) to inlet air

25. Use new cable straps in order to secure the
harness assembly to the cylinder head. Ensure
that the harness assembly is not strained.
Note: Ensure that the harness assembly is clear of
other engine components.
26. Install the mounting bracket for the electronic
Install.
112
RENR9525-01
27. Install the glow plugs. Refer to Disassembly and

Assembly, Glow Plugs - Remove and Install.
28. Install the valve mechanism cover base. Refer to
Cover Base - Remove and Install.
29. Install the electronic unit injectors. Refer to
Disassembly and Assembly, Electronic Unit
Injector - Install.
Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
b. Remove the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove and Install.
30. Install the fuel manifold. Refer to Disassembly

and Assembly, Fuel Manifold (Rail) - Remove
and Install.
NOTICE
31. Install the exhaust manifold. Refer to Disassembly

and Assembly, Exhaust Manifold - Remove and
Install.

component life.
32. If necessary, install the fuel lter base and the

secondary fuel lter. Refer to Disassembly and
Assembly, Fuel Filter Base - Remove and Install.
1. If the crankshaft is installed, use Tooling (A) to

rotate the crankshaft in order to gain access to
the lifters.
33. If necessary, install the fuel priming pump and

the primary fuel lter. Refer to Disassembly and
Assembly, Fuel Priming Pump - Remove and
Install.
34. If the alternator bracket is mounted on the cylinder
head, install the alternator. Refer to Disassembly
and Assembly, Alternator - Install.
35. If necessary, install the air hose to the inlet
connection.
System Coolant - Change for the correct lling
procedure.
37. If necessary, ll the engine oil pan to the correct
level that is indicated on the engine oil level
gauge. Refer to Operation and Maintenance
Manual, Engine Oil Level - Check.
i02933662
Lifter Group - Remove and

Install
g01476632
Illustration 234
Typical example
2. Use Tooling (B) in order to remove lifters (1).

Note: Place a temporary identication mark on each
lifter in order to identify the correct location.
the remaining lifters.
Table 56
Required Tools
Removal Procedure
Table 55
Required Tools
Tool
Part Number
Part Description
Qty
21825576
Telescopic Magnet
Tool
Part Number
Part Description
Qty
21825576
Telescopic Magnet
RENR9525-01
113
End By:
NOTICE
a. Install the camshaft. Refer to Disassembly and


component life.
NOTICE
It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
1. Clean the lifters. Follow Step 1.a through Step 1.c
in order to inspect the lifters. Replace lifters that
are worn or damaged.
b. If the engine is equipped with a balancer, install

Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
i02933593
Camshaft - Remove and Install
a. Inspect the seat of the pushrod in the lifter for

visual wear or damage.
b. Inspect the shank of the lifter for wear or
damage. Refer to Specications, Lifter Group
for more information.
c. Inspect the face of the lifter that runs on the
camshaft for visual wear or damage.
rotate the crankshaft. Rotate the crankshaft to
access to the cylinder block in order to install
lifters (1).
3. Lubricate lifters (1) with clean engine oil.
Removal Procedure
Start By:
a. Remove the rocker shaft and pushrods. Refer to
Pushrod - Remove.
b. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.
NOTICE
component life.
1. The engine should be mounted on a suitable
stand and placed in the inverted position.
Illustration 235
g01476632
Typical example
4. Use Tooling (B) to install lifters (1) to the cylinder

block. Ensure that used lifters are installed in the
correct location.
Illustration 236
Note: The lifters should be free to rotate.

the remaining lifters.
g01266056
Typical example
2. Remove thrust washer (1) from the cylinder block.

Do not remove dowel (2) from the cylinder block
unless the dowel is damaged.
Note: The thrust washer can have one or two Slots
(X).
114
Illustration 237
RENR9525-01
g01266057
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
3. Carefully remove camshaft (3) from the cylinder
block.
4. Do not remove key (4) from camshaft (3) unless
the key is damaged.
Illustration 238
g01266057
4. If necessary, install a new key (4) to camshaft (3).

5. Lubricate the bearing surfaces of camshaft (3)
and lubricate the lobes of the camshaft with clean
engine oil.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
6. Carefully install camshaft (3) into the cylinder
block.
NOTICE
component life.
1. Clean the camshaft and the thrust washer. Inspect
the camshaft and the thrust washer for wear and
for damage. Refer to Specications, Camshaft
for more information. Replace any components
2. Clean the camshaft bearing in the cylinder
block. Inspect the camshaft bearing for wear
and for damage. Refer to Specications,
Camshaft Bearings for more information. If
necessary, replace the camshaft bearing. Refer to
Disassembly and Assembly, Camshaft Bearings
NOTICE
It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
Illustration 239
g01266056
Typical example
7. Lubricate the thrust washer with clean engine oil.

Align Slot (X) in thrust washer (1) with dowel (2)
in the cylinder block. Install thrust washer (1) into
the recess in the cylinder block.
Note: The thrust washer can have one or two slots.
End By:
3. Inspect the lifters for wear and for damage.

Refer to Specications, Lifter Group for more
information. Replace any worn lifters or any
damaged lifters. Refer to Disassembly and
Assembly, Lifter Group - Remove and install.
a. Install the front housing. Refer to Disassembly and

b. Install the rocker shaft and pushrods. Refer to
Pushrod - Install.
RENR9525-01
115
i02933595
Camshaft Gear - Remove and

Install
Removal Procedure
Table 57
Required Tools
Tool
Part Number
A(1)
21825576
27610291
27610289
Gear
27610212
Camshaft Timing Pin
27610211
A(2)
(1)
Part Description
Qty
Illustration 240

g01476661
Typical example

gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position.
Start By:
3. Install Tooling (C) into Hole (Y) in the front housing.

Use Tooling (C) in order to lock the crankshaft in
the correct position.


during repairs.
(2)
b. Remove the front cover. Refer to Disassembly and

Note: Either Tooling (A) can be used. Use the tooling
NOTICE
component life.
NOTICE
mandates.
Illustration 241
g01476663
Typical example
4. Loosen nuts (3) on ALL rocker arms (4). Unscrew

are fully closed.
Note: Failure to ensure that all adjusters are fully
and pistons.

116
RENR9525-01
Table 58
Required Tools
Tool
Part Number
27610212
Camshaft Timing Pin
27610211
21825617
Finger Clock
Illustration 242
g01476666
5. Mark gear (1) and gear (5) in order to show

alignment. Refer to Illustration 242.
Illustration 243
Part Description
Qty
NOTICE
component life.
g01476667
Typical example
Illustration 244
g01478060
Typical example
6. Remove Tooling (B) and Tooling (C) (not Shown).

Remove bolt (7) and washer (6) from camshaft
gear (1).
7. Remove camshaft gear (1) from the camshaft.
Note: If the camshaft gear is a tight t on the nose
of the camshaft, use a prybar in order to remove the
camshaft gear.
8. If necessary, remove the key from the nose of
the camshaft.
2. Install Tooling (C) into Hole (Y) in the cylinder

block. Use Tooling (C) in order to lock the
3. Ensure that the camshaft gear and the key are
clean and free from wear or damage.
4. If necessary, install the key into the nose of the
camshaft.
Note: Ensure that the key is squarely seated.
RENR9525-01
117
8. Remove Tooling (B) and (C) (not shown).

10. Use Tooling (D) to check the backlash for gear
(1) and gear (5). Ensure that the backlash for
the gears is within specied values. Refer to
Specications, Gear Group (Front) for further
information.
11. Use Tooling (D) to check the end play for
camshaft gear (1). Ensure that the end play is
within specied values. Refer to Specications,
Camshaft for further information.
Illustration 245
g01476666
5. Align the keyway in camshaft gear (1) with the key

in the camshaft. Install the camshaft gear onto the
camshaft. Ensure that the timing marks on gear (1)
and gear (5) are in alignment and that the mesh of
the gears is correct. Refer to Illustration 245.
12. Lubricate the teeth of the gears with clean engine

oil.
13. Adjust the valve lash. Refer to Systems Operation,
Testing and Adjusting, Engine Valve Lash Inspect/Adjust.
End By:
i02933594
Camshaft Bearings - Remove

and Install
Illustration 246
g01478078
Removal Procedure
Typical example
Table 59
Required Tools
Tool
Part Number
27610275
Part Description
Bearing Puller
Qty
1
Start By:
Illustration 247
g01794063

Pump - Remove.
Typical example

gear (1) into the front housing.
b. Remove the camshaft. Refer to Disassembly and

7. Install washer (6) and bolt (7) to the camshaft gear.
118
RENR9525-01
NOTICE
component life.
Illustration 249
g01266512
2. Lubricate the bearing housing in the cylinder block

with clean engine oil.
g01270437
Illustration 248
3. Accurately align the two oil Holes (X) in camshaft

bearing (1) with the two oil holes in the cylinder
block.
1. Inspect camshaft bearing (1). Refer to

Specications, Camshaft Bearings for more
information.
Note: The Groove (Y) in the camshaft bearing must

be to the top of the cylinder block.
2. If camshaft bearing (1) is worn or damaged use

Tooling (A) in order to remove the camshaft
bearing from the cylinder block.
4. Use Tooling (A) in order to install camshaft bearing

(1) into the cylinder block. Install the camshaft
bearing so that the front edge of the bearing is
ush with the face of the recess in the cylinder
block.
Note: Remove the camshaft bearing from the front of

the cylinder block.
Note: Ensure that all oil holes are correctly aligned.

If the oils are not correctly aligned, the camshaft
bearing should be removed.
Table 60
End By:
Required Tools
Tool
Part Number
27610275
Part Description
Bearing Puller
Qty
1
NOTICE
component life.
a. Install the camshaft. Refer to Disassembly and

- Install.
1. Clean the bearing housing in the cylinder block.

Ensure that the oil holes in the bearing housing
are free from debris.
RENR9525-01
119
i02933623
Engine Oil Pan - Remove and

Install
(Aluminum and Pressed Steel
Oil Pans)
Removal Procedure
NOTICE
component life.
NOTICE
mandates.
Illustration 251
g01797036
Typical example
1. Place a suitable container below the engine

oil pan. Remove drain plug (5) and drain the
engine lubricating oil. Refer to Operation and
Maintenance Manual, Engine Oil and Filter Change for the correct procedure.
2. Remove O-ring seal (11) from drain plug (5).
3. Disconnect breather hose (1) from clip (6).
Position the breather hose away from the engine
oil pan.
4. If necessary, remove the assembly of the dipstick
tube. Loosen nut (3) and remove tube assembly
(2). Remove seal (4) from the tube assembly.
Note: Identify the position and orientation of the tube
assembly.
5. Support the assembly of the engine oil pan. Mark
the position of clip (6). Loosen bolts (9) and bolts
(10). Remove the clip and remove the bolts.
6. Remove engine oil pan (8) and remove gasket (7)
from the cylinder block.
Illustration 250
g01478088
Typical example
120
RENR9525-01
Table 61
Required Tools
Tool
Part Number
B
C
Part Description
Qty
Guide Bolt
M8 by 100 mm
21826038
POWERPART
Silicon Rubber Sealant
21820117
POWERPART
Threadlock and NutLock
NOTICE
Illustration 253
g01251763
Typical example

component life.
1. Ensure that the face of the cylinder block is clean
and free from damage.
Illustration 254
g01803754
Typical example
4. Apply a bead of Tooling (B) to Positions (Y) on the

cylinder block.
Note: If the bridge piece for the cylinder block has
just been installed, the engine oil pan must be
installed before Tooling (B) has cured.
Illustration 252
g01251768
Typical example
2. Install Tooling (A) to Positions (X) in the cylinder

block.
3. Ensure that the engine oil pan is clean and free
from damage.
RENR9525-01
Illustration 255
121
g01797036
Illustration 256
g01478088
Typical example
Typical example
5. Position a new gasket (7) onto engine oil pan (8).
12. Install a new O-ring seal to drain plug (5). Install

the drain plug to the engine oil pan. Tighten the oil
drain plug to a torque of 34 Nm (25 lb ft).
6. Align the assembly of the engine oil pan with

Tooling (A). Install the assembly of the engine oil
pan to the cylinder block. Install clip (6) in the
correct position.
13. If necessary, follow Step 13.a through Step 13.c

in order to install the assembly of the dipstick tube.
a. Install a new seal (4) to tube assembly (2).
b. Apply Tooling (C) to nut (3). Install the tube

assembly to the engine oil pan.
9. Apply Tooling (C) to bolts (9).

10. Install bolts (9) and the remaining bolts (10).
11. Tighten bolts (9) and bolts (10) to a torque of
22 Nm (16 lb ft). Refer to Specications, Engine
Oil Pan for the correct tightening sequence.
Note: Ensure that the orientation of the tube

assembly is correct.
c. Tighten nut (3) to a torque of 18 Nm (13 lb ft).
Install the dipstick.
14. Fill the engine oil pan to the correct level. Refer to
and Filter - Change for the correct procedure.
i02933622
Engine Oil Pan - Remove and

Install
(Cast Iron Oil Pan)
Removal Procedure
Note: In order to remove a cast iron oil pan, the
engine must be removed from the machine.
122
RENR9525-01
5. Mark the position of clip (6). Refer to Illustration

257. Loosen the bolt that secures the clip and
remove the clip.
NOTICE
component life.
NOTICE
mandates.
1. Ensure that the engine lubricating oil is drained.
Engine Oil and Filter - Change for the correct
procedure.
2. The engine should be mounted in a suitable stand
and placed in the inverted position.
Illustration 258
g01251978
Typical example
6. Remove nuts (10) and bolts (9).

Note: The bolts are different lengths. Note the
position of the different bolts.
7. Attach a suitable lifting device to engine oil pan
(8). Support the weight of the engine oil pan. The
engine oil pan weighs approximately 41 kg (90 lb).
8. Use the lifting device to remove engine oil pan (8)
9. Remove gasket (7) from the cylinder block.
Illustration 257
g01478088
Typical example
10. If necessary, remove drain plug (5). Remove

O-ring seal (11) from oil drain plug (5).
3. Disconnect breather hose (1) from clip (6).

Position the breather hose away from the engine
oil pan.
Note: Identify the position and orientation of the tube
assembly before removal.
4. Remove the assembly of the dipstick tube. Loosen
nut (3) and remove tube assembly (2). Remove
seal (4) from the tube assembly.
RENR9525-01
123
Table 62
Required Tools
Tool
Part Number
Part Description
Qty
21826038
POWERPART
21820117
POWERPART
Threadlock and NutLock
Straight Edge
Note: In order to install a cast iron oil pan, the engine

must be removed from the machine.
Illustration 260
g01803754
Typical example
NOTICE
3. Apply a bead of Tooling (A) to Positions (Y) on the

cylinder block.

component life.
1. Ensure that the face of the cylinder block is clean
and free from damage. Inspect the studs in the
cylinder block for damage. If necessary, replace
the studs.
Note: If the bridge piece for the cylinder block has

just been installed, the engine oil pan must be
installed before Tooling (A) has cured.
2. Ensure that the engine oil pan is clean and free

from damage.
Illustration 259
g01251763
Typical example
Illustration 261
g01251978
Typical example
4. Align a new gasket (7) with the studs in the

cylinder block. Install the gasket to the cylinder
block.
5. Attach a suitable lifting device to engine oil pan
(8). The engine oil pan weighs approximately
41 kg (90 lb).
124
RENR9525-01
6. Use the lifting device to align engine oil pan (8)

with the studs in the cylinder block. Install the
engine oil pan to the cylinder block. Remove the
lifting device from the engine oil pan.
10. If necessary, install a new O-ring seal to drain

plug (5). Install drain plug (5) to engine oil pan
(8). Tighten the drain plug to a torque of 34 Nm
(25 lb ft).
7. Install bolts (9) and nuts (10) nger tight. Install

clip (6).
11. Follow Step 11.a through Step11.c in order to

install the assembly of the dipstick tube.
a. Install a new seal (4) to tube assembly (2).
b. Apply Tooling (B) to nut (3). Install the tube
assembly to the engine oil pan.
Note: Ensure that the orientation of the tube
assembly is correct.
c. Tighten the nut to a torque of 18 Nm (13 lb ft).
Install the dipstick .
12. Install breather hose (1) to clip (6).
Illustration 262
g01251982
Typical example
8. Align the rear face of engine oil pan (8) to the rear
face of cylinder block (12). Use Tooling (C) and
a feeler gauge in order to check the alignment
between the engine oil pan and the cylinder
block. The maximum step that is allowed between
the cylinder block and the sump is 0.1 mm
(0.004 inch).
9. Tighten bolts (9) and nuts (10) to a torque of
22 Nm (16 lb ft). Refer to Specications, Engine
Oil Pan for the correct tightening sequence.
Note: After the engine has been installed, ensure that

the engine oil pan is lled with lubricating oil to the
correct level. Refer to Operation and Maintenance
Manual, Engine Oil and Filter - Change for the
correct procedure.
i02933591
Balancer - Remove
Removal Procedure
Table 63
Required Tools
Tool
Part
Number
21825576
27610211
27610225
Timing Pin (Balancer)
Puller (Two Leg)
Part Description
Qty
Start By:
Install.
b. Remove the front cover. Refer to Disassembly
and Assembly, Front Cover - Remove and Install.
Illustration 263
Typical example
g01251772
Note: In order to remove the balancer, the engine

must be removed from the machine. The engine
should be mounted in a suitable stand and placed
in the inverted position.
RENR9525-01
125
NOTICE
component life.
NOTICE
mandates.
1. Use Tooling (A) in order to rotate the crankshaft
so that number one piston is at the top center
position.
Illustration 265
g01259635
Typical example

4. Remove the gasket from the suction pipe.
Illustration 264
g01259627
Typical example
2. Install Tooling (B) through Hole (X) in the front

housing. Use Tooling (B) in order to lock the
Illustration 266
g01252310
Typical example
5. Install Tooling (C) into balancer (1). Ensure that

Tooling (C) is engaged into the hole in drive shaft
(5).
6. Attach a suitable lifting device to balancer (1).
Support the weight of the balancer. The balancer
weighs approximately 23 kg (51 lb).
7. Remove bolts (4). Use the lifting device to remove
the balancer.
126
Illustration 267
RENR9525-01
g01259636
g01259631
Illustration 269
Typical example
8. Do not remove dowel (6) and dowel (7) unless the

dowels are damaged.
Note: The balancer unit is not a serviceable item.
The engine oil pump and the engine oil relief valve
are the only serviceable parts of the balancer.
3. Remove nut (12). Use Tooling (D) in order to

remove gear (13) from the shaft of the oil pump.
Note: Do not use a timing pin to lock the balancer in
order to loosen nut (12).
4. Remove bolts (14) and remove front cover (15).
1. Remove the engine oil relief valve. Refer to

Valve - Remove and Install.
5. Remove outer rotor (17) and remove inner rotor

(16).
Note: Mark the direction of rotation of the rotors.
i02933590
Balancer - Install
Assembly Procedure
Table 64
Required Tools
Tool
Part Number
21820117
Part Description
POWERPART
Qty
1
NOTICE
component life.
1. Ensure that all components of the engine oil pump
are clean and free from wear or damage.
Illustration 268
g01478152
Typical example
2. Remove bolt (8) and hub (9). Remove idler gear

(10) and thrust washer (11).
RENR9525-01
127
7. Ensure that the threads of bolt (8) are clean and

dry. Apply Tooling (E) to the threads of the bolt.
Install bolt (8). Tighten the bolt to a torque of
26 Nm (19 lb ft).
8. Check the end play of idler gear (10). Refer to
Specications, Engine Oil Pump.
9. Install the engine oil relief valve . Refer to
Valve - Remove and Install for further information.
Table 65
Required Tools
Tool
Part Number
27610211
27610225
Timing Pin (Balancer)
21825617
Finger Clock
Guide Studs
(M10 by 75 mm)
F
G
Illustration 270
Part Description
Qty
g01478152
Typical example
2. Install inner rotor (16) and install outer rotor (17).

Used rotors should be installed in the original
direction of rotation. Check the clearance between
the outer rotor and the body of the oil pump.
Check the clearance between the inner rotor and
the outer rotor. Check the end play of the rotor
assembly. Refer to Specications, Engine Oil
Pump for more information.
3. Lubricate the assembly of the oil pump with clean
engine oil. Install front cover (15). Install bolts (14).
4. Ensure that the shaft of the oil pump is clean
and dry. Position gear (13) onto the shaft. Install
nut (12). Tighten the nut to a torque of 95 Nm
(70 lb ft).
Illustration 271
g01259627
1. Ensure that No. 1 piston is at the top center

position and that Tooling (B) is installed to Position
(X) in the front housing.
2. Clean the faces of the cylinder block.
Note: Do not use a timing pin to lock the balancer in

order to tighten nut (12).
5. Lubricate hub (9), thrust washer (11) and the bush
of idler gear (10) with clean engine oil. Install hub
(9) and thrust washer (11) to idler gear (10).
Note: Ensure the correct orientation of the idler gear.
6. Install the assembly of the idler gear to balancer
(1).
128
RENR9525-01
7. Use the lifting device to align balancer (1) with

Tooling (G). Install the balancer to the cylinder
block. Ensure that dowels (6) and (7) are aligned
with the holes in the cylinder block. Ensure that
gear (10) and the crankshaft gear mesh. Remove
the lifting device.
Illustration 272
g01252312
3. Install Tooling (G) to the cylinder block.
Illustration 275
g01259635
8. Install bolts (4) to balancer (1) nger tight.
Illustration 273
g01260306
4. Ensure that dowel (6) and dowel (7) are seated in

the housing of balancer (1).
9. Remove Tooling (G) and install remaining bolts (4).

11. Install suction pipe (2) and a new gasket to
balancer (1).
22 Nm (16 lb ft).
13. Use Tooling (F) in order to check the backlash
between gears (10) and (13). Refer to Illustration
273. Refer to Specications, Engine Oil Pump.
14. Use Tooling (F) in order to check the backlash
between gear (10) and the crankshaft gear. Refer
to Specications, Gear Group - Front for further
information.
Illustration 274
g01252310
5. Install Tooling (C) to balancer (1). Ensure that

Tooling (C) is engaged into shaft (5).
6. Attach a suitable lifting device to the balancer. The
balancer weighs approximately 23 kg (51 lb).
End By:
and Assembly , Engine Oil Pan - Remove and
Install.
b. Install the front cover. Refer to Disassembly and
RENR9525-01
129
i02933663
Piston Cooling Jets - Remove

and Install
3. Repeat Step 1 and Step 2 for the remaining piston

cooling jets.
Table 67
Required Tools
Removal Procedure
Tool
Part Number
Part Description
Qty
A(1)
21825576
27610291
27610289
Gear
Table 66
Required Tools
Tool
Part Number
Part Description
Qty
A(1)
21825576
27610291
27610289
Gear
A(2)
(1)
(2)

A(2)
(1)
(2)


NOTICE
Start By:
Pump - Remove.

component life.

NOTICE
component life.
rotate the crankshaft in order to gain access to the
appropriate piston cooling jet.
Illustration 277
g01265615
1. Clean the piston cooling jets and inspect the

piston cooling jets for damage. Ensure that the
valve is free to move within each piston cooling
jet. Replace any damaged piston cooling jets.
2. If the crankshaft is installed, use Tooling (A)
to rotate the crankshaft in order to access the
mounting ange for the piston cooling jet.
3. Position piston cooling jet (2) in the cylinder block.
Install bolt (1). Tighten the bolt to a torque of
9 Nm (80 lb in).
4. Repeat Step 2 and Step 3 for the remaining piston
cooling jets.
Illustration 276
g01265615
Typical example
2. Remove bolt (1) and piston cooling jet (2) from

the cylinder block.
5. If the cylinder head has been removed, It is

possible to check the alignment of the piston
cooling jets. Refer to Specications, Piston
Cooling Jet Alignment for more information.
130
RENR9525-01
Note: It is not possible to check the alignment of the

piston cooling jets with the cylinder head in position.
2. Use Tooling (B) to remove the carbon ridge from

the top inside surface of the cylinder bore.
End By:
a. If the engine is equipped with a balancer, install
- Install.
i02933667
Pistons and Connecting Rods

- Remove
Removal Procedure
Table 68
Illustration 278
Required Tools
Tool
Part Number
Part Description
Qty
A(1)
21825576
27610291
27610289
Gear
27610274
Ridge Reamer
A(2)
B
(1)
(2)

Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly , Cylinder Head - Remove.
b. If the engine is equipped with a balancer, remove
g01479383
3. The connecting rod and the connecting rod cap

should have an etched Number (X) on the side.
The number on the connecting rod and the
connecting rod cap must match. Ensure that the
connecting rod and connecting rod cap (2) are
marked for the correct location. If necessary, make
a temporary mark on the connecting rod and the
connecting rod cap in order to identify the cylinder
number.
Note: Do not stamp the connecting rod assembly.
Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
4. Remove bolts (1) and remove connecting rod cap
(2) from the connecting rod.
c. Remove the piston cooling jets. Refer to

Disassembly and Assembly , Piston Cooling Jets
NOTICE
Illustration 279

component life.
1. Use Tooling (A) to rotate the crankshaft until the
crank pin is at the bottom center position.
g01479386
Typical example
5. Carefully push piston (3) and the connecting rod

assembly out of the cylinder bore. Lift the piston
out of the top of the cylinder block.
RENR9525-01
131
Note: Do not push on the fracture split surfaces of

the connecting rod as damage may result.
6. Temporarily install connecting rod cap (2) and
bolts (1) to the connecting rod when the assembly
is out of the engine. Tighten bolts (1) to a torque
Note: Fracture split connecting rods should not be left
without the connecting rod caps installed. Ensure that
the etched number on connecting rod cap matches
the etched number on connecting rod. Ensure the
correct orientation of the connecting rod cap.
pistons and connecting rods.
i02933665

- Disassemble
Table 69
Illustration 280
g01244067
Illustration 281
g01253091
Required Tools
Tool
Part Number
Part Description
Qty
Circlip Pliers
Piston Ring Expander
Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Remove.
NOTICE
component life.
1. Make a temporary mark on the components of
the piston and connecting rod assembly. This
will ensure that the components of each piston
and connecting rod assembly can be reinstalled
in the original cylinder. Mark the underside of the
piston on the front pin boss. Do not interchange
components.
Typical example
2. Place the piston and connecting rod assembly on

a suitable surface with the connecting rod upward.
Use Tooling (A) in order to remove circlips (5).
132
RENR9525-01
Note: Forged Marks (X) identify the front of the

connecting rod assembly. The forged marks should
be used for the purposes of orientation.
7. Inspect the connecting rod for wear or damage. If

necessary, replace connecting rod (6) or replace
bush (7) for the piston pin.
3. Remove piston pin (8) and connecting rod (6) from

piston (4).
Note: If the connecting rod or the bush for the piston

pin are replaced, rst identify the height grade of the
connecting rod. Refer to Specications, Connecting
Rods.
Note: If the piston pin cannot be removed by hand,

heat the piston to a temperature of 45 5 C
(113 9 F). Do not use a torch to heat the piston.
Note the orientation of the connecting rod and the
piston.
4. Place the piston on a suitable surface with the
crown upward. Use Tooling (B) in order to remove
compression rings (1) and (2), and oil control ring
(3) from piston (4).
8. Repeat Step 1 through Step 7 in order

to disassemble the remaining pistons and
connecting rods.
i02933664

- Assemble
Note: Identify the position and orientation of

compression rings (1) and (2), and oil control ring (3).
Assembly Procedure
Table 70
Required Tools
Tool
Part Number
Part Description
Qty
Circlip Pliers
Piston Ring Expander
NOTICE
Illustration 282
g01244068
5. Remove bolts (12) and connecting rod cap (11)

from connecting rod (6). Discard the bolts.
Note: Fracture split connecting rods should not be left
without the connecting rod caps installed. After the
disassembly procedure for the piston and connecting
rod is completed, carry out the assembly procedure
and the installation procedure as soon as possible.
Connecting Rods - Assemble and Disassembly and
Assembly, Piston and Connecting Rods - Install.

component life.
6. Remove the lower half of connecting rod bearing

(10) from connecting rod cap (11). Remove the
upper half of connecting rod bearing (9) from
connecting rod (6). Keep the connecting rod
bearings together.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distributor.
RENR9525-01
133
c. Use Tooling (B) to install intermediate

compression ring (2) into the second groove in
piston (4). The word TOP must be upward.
The chamfer on the inner face must be
downward.
d. Use Tooling (B) to install top compression ring
(1) into the top groove in piston (4). The word
TOP must be upward.
e. Position the piston ring gaps at 120 degrees
away from each other.
Note: A new piston assembly is supplied with new
piston rings.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distributor.
Illustration 283
g01244067
3. If the connecting rod assembly or the bush for

the piston pin have been replaced, ensure that
the height grade of the connecting rod is correct.
Refer to Specications, Connecting Rods for
4. Lubricate bush (7) and lubricate the bore for the
piston pin in piston (4) with clean engine oil.
Illustration 284
g01155119
2. If the original piston is assembled, follow Step 2.a

through Step 2.e in order to install the piston rings.
a. Position the spring for oil control ring (3) into
the oil ring groove in piston (4). The central wire
must be located inside the end of the spring.
b. Use Tooling (B) to install oil control ring (3) over
the spring.
Note: Ensure that the central wire is 180 degrees
from the ring gap.
Illustration 285
g01244172
5. Place the piston on a suitable surface with the

crown downward. Install connecting rod (6) and
piston pin (8) to piston (4). Ensure that square
boss (13) on the piston, and forged Mark (X) on
the connecting rod are in the correct position. See
illustration 285.
Note: If the piston pin cannot be installed by hand,
heat the piston to a temperature of 45 5C
(113 9F).
6. Use Tooling (A) in order to install circlips (5) to the
piston pin bore in piston (4).
134
RENR9525-01
Note: Ensure that the circlips are seated in the

grooves in the piston.
Note: Fracture split connecting rods should not

be left without the connecting rod caps installed.
After the assembly procedure for the piston and
connecting rod is completed, carry out the installation
procedure as soon as possible.
End By:
a. Install the pistons and the connecting rods.
Connecting Rods - Install.
i02933666
Illustration 286
g01244068

- Install
Table 71
Required Tools
Tool
Part Number
A(1)
21825576
Crankshaft Turning
Tool
27610291
27610289
Gear
21825491
Piston Ring
Compressor
21825607
Angle gauge
A(2)
Illustration 287
g01001160
Aligning the connecting rod bearing in the center of the connecting

rod
(1)
7. Install the upper half of connecting rod bearing (9)

to connecting rod (6). Ensure that the connecting
rod bearing is centralized in the connecting rod.
Note: New connecting rod bearings are supplied with
an alignment tool. If new connecting rod bearings
are installed, use the tool to align the connecting rod
bearing in the connecting rod.
8. Install the lower half of connecting rod bearing
(10) to connecting rod cap (11). Ensure that
the connecting rod bearing is centralized in the
connecting rod cap. Refer to Illustration 287.
(2)
Part Description
Qty


NOTICE
component life.
NOTICE
Discard all used connecting rod bolts.

an alignment tool. If new connecting rod bearings
are installed, use the tool to align the connecting rod
bearing in the connecting rod cap.
1. If the connecting rod caps were temporarily

installed, remove the connecting rod caps. If
necessary, thoroughly clean all of the components.

piston and connecting rod assemblies.
2. Apply clean engine oil to the cylinder bore, to the

piston rings, to the outer surface of the piston and
to the connecting rod bearings.
RENR9525-01
135
Note: Install the connecting rod bearings dry

when clearance checks are performed. Refer to
Disassembly and Assembly, Bearing Clearance Check. Apply clean engine oil to the connecting rod
bearings during nal assembly.
crankshaft pin is at the bottom center position.
Lubricate the crankshaft pin with clean engine oil.
Illustration 289
g01479452
Typical example
Illustration 288
g01253096
Typical example
4. Ensure that the gaps for the piston rings are at

120 degrees away from each other. Install Tooling
(B) onto piston (3).
Note: Ensure that Tooling (B) is installed correctly
and that the piston can easily slide from the tool.
Ensure that the piston and the connecting rod
assembly are installed in the correct cylinder. The
arrow on the top of the piston must be toward the
front of the engine.
6. Install connecting rod cap (2) onto the connecting

rod.
Note: Ensure that etched Number (X) on the
connecting rod cap matches the etched number on
the connecting rod. Ensure the correct orientation of
connecting rod cap (2).
7. Install new bolts (1) to the connecting rod. Tighten
the bolts evenly to a torque of 18 Nm (13 lb ft).
8. Tighten the bolts evenly to a torque of 70 Nm
(52 lb ft).
5. Carefully push the piston and the connecting rod

assembly into the cylinder bore and onto the
crankshaft pin.
9. Use Tooling (B) to turn the bolts through an

additional 120 degrees.
Note: Do not damage the nished surface of the

crankshaft pin.
10. Ensure that the installed connecting rod assembly

has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
the remaining pistons and connecting rods.
Note: If all pistons and connecting rods require
replacement the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders. 1
with 4 and 2 with 3. Ensure that both pairs of the
pistons and connecting rods are installed before
changing from one pair of cylinders to another
pair of cylinders.
12. Check the height of the pistons above the top face
of the cylinder block. Refer to Systems Operation,
Testing and Adjusting, Piston Height - Inspect for
136
RENR9525-01
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, Piston Cooling Jets - Remove
and Install.
c. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02933597
Connecting Rod Bearings Remove

(Connecting rods in position)
Note: If all connecting rod bearings require

be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed
before changing from one pair of cylinders to
another pair of cylinders.Refer to Disassembly and
Assembly, Connecting Rod Bearings - Install.
crank pin is at the bottom center position.
If necessary, remove the glow plugs. Refer
to Disassembly and Assembly, Glow Plugs Remove and Install.
Note: Removal of the glow plugs aids removal of the
connecting rod bearings. It is not essential.
Removal Procedure
Table 72
Required Tools
Tool
Part Number
Part Description
Qty
A(1)
21825576
27610291
27610289
Gear
A(2)
(1)
(2)

Start By:
Illustration 290
g01479383
Illustration 291
g01253101

NOTICE
component life.
NOTICE
RENR9525-01
137
2. The connecting rod and the connecting rod cap

should have an etched Number (X) on the side.
The number on the connecting rod and the
connecting rod cap must match. If necessary,
make a temporary mark on connecting rod (5)
and connecting rod cap (2) in order to identify the
cylinder number.
Note: Do not punch identication marks onto fracture
split connecting rods. Do not stamp identication
marks onto fracture split connecting rods.
3. Remove bolts (1) and connecting rod cap (2) from
connecting rod (5). Discard the bolts.
4. Remove the lower half of connecting rod bearing
(3) from connecting rod cap (2). Keep the
connecting rod bearing and the connecting rod
cap together.
5. Carefully push the piston and connecting rod
assembly into the cylinder bore until connecting
rod (5) is clear of the crankshaft. Remove the
upper half of connecting rod bearing (4) from
connecting rod (5). Keep the bearings together.

NOTICE
component life.
NOTICE
1. Inspect the pins of the crankshaft for damage.
If the crankshaft is damaged, replace the
crankshaft or recondition the crankshaft. Refer
to Disassembly and Assembly, Crankshaft
- Remove and Disassembly and Assembly,
Crankshaft - Install. Ensure that the connecting
rod bearings are clean and free from wear or
damage. If necessary, replace the connecting rod
bearings.
Note: Do not push on the fracture split surfaces of the

connecting rod as damage may result. Do not allow
the connecting rod to contact the piston cooling jet.
Fracture split connecting rods should not be left
without the connecting rod caps installed. After the
removal procedure for the connecting rod bearings
is complete, carry out the installation procedure
as soon as possible. Refer to Disassembly and
i02933596
Illustration 292
g01260354
g01001160
Connecting Rod Bearings Install

(Connecting rods in position)
Table 73
Required Tools
Tool
Part Number
Part Description
Qty
A(1)
21825576
Illustration 293
27610291
Aligning the bearing in the center of the connecting rod
27610289
Gear
21825607
Angle Gauge

an alignment tool. If new bearings are installed, use
the tool to align the bearing in the connecting rod.
A(2)
B
(1)
(2)

138
RENR9525-01
2. Install the upper half of connecting rod bearing

(4) to connecting rod (5). Ensure that the bearing
is centralized in the connecting rod. Refer to
Illustration 293.
The ends of the bearing must be centered in the
connecting rod. The ends of the bearing must be
equally positioned in relation to the faces of the
connecting rod.
3. Clean the connecting rod cap. Install lower
connecting rod bearing (3) to connecting rod cap
(2). Ensure that the connecting rod bearing is
centralized in the connecting rod cap. Refer to
Illustration 293.
The ends of the lower connecting rod bearing
must be centered in the connecting rod cap. The
ends of the lower connecting rod bearing must be
equally positioned in relation to the faces of the
connecting rod cap.
4. Lubricate upper connecting rod bearing (4) with
clean engine oil.
5. If necessary, use Tooling (A) in order to rotate the
crankshaft until the crankshaft pin is at the bottom
dead center position.
6. Carefully pull connecting rod (5) against the
crankshaft pin.
Note: Do not allow the connecting rod to contact the
piston cooling jet.
7. Lubricate the pin of the crankshaft and lubricate
lower connecting rod bearing (3) with clean engine
oil.
8. Install connecting rod cap (2) to connecting rod

(5).
Note: Ensure that etched Number (X) on connecting
rod cap (2) matches etched Number (X) on
connecting rod (5). Ensure the correct orientation of
the connecting rod cap. The forged Marks (Y) on the
connecting rod and the connecting rod cap should be
on the same side. Refer to Illustration 292.
9. Install new bolts (1). Tighten the bolts evenly to a
Note: Do not reuse the old bolts in order to secure
the connecting rod cap.
10. Tighten the bolts evenly to a torque of 70 Nm
(52 lb ft).
11. Use Tooling (B) to turn the bolts through an
12. Ensure that the installed connecting rod assembly
has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
connecting rod bearings.
Note: If all connecting rod bearings require
be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that both pairs of
the connecting rod bearings are installed before
changing from one pair of cylinders to another
pair of cylinders..
14. If the glow plugs were removed, install the glow
plugs. Refer to Disassembly and Assembly, Glow
Plugs - Install.
End By:
Illustration 294
g01479452
Typical example
RENR9525-01
139
i02933605
Crankshaft Main Bearings Remove and Install

(Crankshaft in position)
Removal Procedure
Table 74
Required Tools
Tool
Part Number
Part Description
Qty
A(1)
21825576
27610291
27610289
Gear
A(2)
(1)
(2)
Illustration 295
g01490997
Typical example
1. Remove allen head screws (1). Remove bridge

piece (2).

Start By:
b. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Remove.
Illustration 296

g01253719
Typical example
NOTICE
This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are removed.
NOTICE
Illustration 297

component life.
g01253146
Typical example
2. Ensure that the main bearing cap is marked for

the correct location and orientation.
3. Remove bolts (3). Remove main bearing cap (4)
140
RENR9525-01
4. Remove lower main bearing (5) from main bearing

cap (4). Keep the main bearing and the main
bearing cap together. Take care not to displace
dowels (6).
Note: The lower main bearing is a plain bearing that
has no oil holes. The dowels may remain in the main
bearing cap or in the cylinder block.
Illustration 298
Illustration 300
g01253145
Illustration 301
g01889993
g01253137
Typical example
No. 1 Upper Main Bearing

Illustration 299
g01253142
Typical example
5. For number three main bearing cap, remove thrust

washers (7).
6. For number three main bearing, remove thrust
washers (8) from the cylinder block. In order to
remove the thrust washers, push the crankshaft
toward the front of the engine or push the
crankshaft toward the rear of the engine. Use
Tooling (A) in order to rotate the crankshaft. If
necessary, use a suitable tool to free the thrust
washers.
7. Push out upper main bearing (9) with a suitable

tool from the side opposite the locating tab.
Carefully rotate the crankshaft while you push on
the bearing . Remove upper main bearing (9) from
the cylinder block. Keep the bearings together.
Note: Do not damage the machined surfaces of the
crankshaft during removal of the upper main bearing.
Number 1 upper main bearing has an oil slot. See
Illustration 303. All other upper main bearings have a
groove and two oil holes.
Note: Do not damage the machined surfaces of the

crankshaft during removal of the thrust washers.
RENR9525-01
141
Table 75
Required Tools
Tool
Part Number
21825617
Part Description
Qty
Straight Edge
5 mm Allen Socket
21826038
POWERPART
Silicon Rubber
Sealant
NOTICE
This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are removed.
NOTICE
component life.
1. Ensure that the main bearings are clean and free
from wear or damage. If necessary, replace the
main bearings.
Illustration 303
g01889993
3. Lubricate the crankshaft journal and upper main

bearing (9) with clean engine oil. Slide upper main
bearing (9) into position between the crankshaft
journal and the cylinder block. Ensure that the
locating tab for the upper main bearing is correctly
seated in the slot in the cylinder block.
Note: Number 1 upper main bearing has an oil slot.
See Illustration 303. All other upper main bearings
have a groove and two oil holes.
2. Clean the journals of the crankshaft. Inspect

the journals of the crankshaft for damage. If
necessary, replace the crankshaft or recondition
the crankshaft.
Illustration 304
g01261200
Typical example
Illustration 302
Typical example
g01253145
4. For number three main bearing, ensure that thrust

washers (8) are clean and free from wear or
damage. If necessary, replace the thrust washers.
Lubricate thrust washers (8) with clean engine oil.
Slide the thrust washers into position between the
crankshaft and the cylinder block. The grooves in
the thrust washers must be located against the
crankshaft.
142
Illustration 305
RENR9525-01
g01253146
Illustration 307
g01253719
Typical example
Typical example
5. Install lower main bearing (5) into main bearing

cap (4). Ensure that the locating tab for the lower
main bearing is correctly seated into the slot in
the bearing cap.
7. Lubricate the crankshaft journal and the lower

main bearing with clean engine oil. Install main
bearing cap (4) to the cylinder block.
Note: The lower main bearing is a plain bearing that

has no oil holes.
Note: Ensure the correct orientation of the main

bearing cap. The locating tab for the upper and the
lower bearing should be on the same side of the
engine.
8. Lubricate the threads of bolts (3) with clean engine
oil. Lubricate the underside of the heads of the
bolts with clean engine oil.
9. Install bolts (3) to main bearing cap (4). Evenly
tighten the bolts in order to pull cap (5) into
position. Ensure that the cap is correctly seated.
Note: Do not tap the main bearing cap into position
as the bearing may be dislodged.
Illustration 306
g01253137
Typical example
6. For number three main bearing cap, ensure that

thrust washers (7) are clean and free from wear or
Lubricate thrust washers (7) with clean engine
oil. Place the thrust washers into position on the
main bearing cap. Ensure that the locating tab is
correctly seated in the main bearing cap.
Illustration 308
g01253186
Typical example
RENR9525-01
143
11. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
crankshaft end play. The permissible crankshaft
end play is 0.17 to 0.41 mm (0.007 to 0.016 inch).
14. Apply Tooling (E) to Cavities (Y) in bridge piece

(2). Continue to apply Tooling (E) until sealant
extrudes from Cavities (X).
Note: If the oil pan will not be installed immediately,
ensure that the face of the bridge piece and the
cylinder block are left free of sealant.
End By:
i02933602
Crankshaft - Remove
Illustration 309
g01253836
Typical example
Removal Procedure
12. Follow Step 12.a through Step 12.d in order to

install the bridge piece.
Table 76
Required Tools
a. Ensure that the recess in the cylinder block

and the bridge piece are clean, dry and free
from old sealant.
b. Install bridge piece (2) and allen head screws
(1). Tighten the allen head screws nger tight.
c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
cylinder block.
d. Use Tooling (D) to tighten allen head screws
(1) to a torque of 16 Nm (12 lb ft).
13. Install the crankshaft rear seal. Refer to
Seal - Install.
Tool
Part Number
Part Description
Qty
Lifting Strap
Start By:
a. Remove the rocker shaft and pushrods. Refer to
Pushrod - Remove.
b. Remove the front housing. Refer to Disassembly
c. Remove the crankshaft rear seal. Refer to
Seal - Remove.
d. If the engine is equipped with a balancer, remove
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.
Illustration 310
g01344584
Typical example
144
RENR9525-01
5. Remove bolts (3) and main bearing caps (4) from

the cylinder block.
NOTICE
component life.
1. The engine should be mounted on a suitable
2. If necessary, remove the cylinder head. Refer
to Disassembly and Assembly, Cylinder Head Remove. Remove the pistons and connecting
rods. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Remove.
If the cylinder head, the pistons and the
connecting rods have not been removed, remove
the connecting rod caps. Refer to Disassembly
and Assembly, Connecting Rod Bearings Remove.
Illustration 313
g01253146
Typical example
Illustration 314
g01253137
Typical example
Illustration 311
g01439628
Typical example
3. Remove allen head screws (1). Remove bridge

piece (2).
4. Ensure that the main bearing caps are marked for
the location and orientation.
Illustration 312
6. Remove lower main bearings (5) from main

bearing caps (4). Take care not to displace dowels
(6). For number three main bearing cap, remove
thrust washers (7). Keep the lower main bearings
and the thrust washers with the respective main
bearing caps.
Note: The lower main bearings are plain bearings
that have no oil holes. The dowels may remain in the
main bearing cap or in the cylinder block.
g01253719
Typical example
RENR9525-01
Illustration 315
145
g01254099
Typical example
7. Attach Tooling (A) and a suitable lifting device to

crankshaft (8). Carefully lift the crankshaft out of
the cylinder block. The weight of the crankshaft is
approximately 30 kg (66 lb).
Note: Do not damage any of the nished surfaces
on the crankshaft. When the crankshaft is removed
from the engine, the crankshaft must be supported
on a suitable stand in order to prevent damage to
the crankshaft timing ring.
Illustration 317
g01889993
8. Remove upper main bearings (9) from the cylinder

block. Keep the upper main bearings with the
respective main bearing caps.
See Illustration 317. All other upper main bearings
have a groove and two oil holes.
9. Remove thrust washers (10) from number three
main bearing in the cylinder block.
10. If necessary, remove the crankshaft timing ring.
Timing Ring - Remove and Install.
11. If necessary, remove the crankshaft gear. Refer
to Disassembly and Assembly, Crankshaft Gear
Illustration 316
g01254104
Typical example
146
RENR9525-01
Crankshaft - Install
5. Clean the crankshaft bearings and the thrust

washers. Inspect the bearings and the thrust
washers for wear or damage. If necessary, replace
the bearings and the thrust washers.
Note: If the crankshaft bearings are replaced, check

whether oversize bearings were previously installed.
If the thrust washers are replaced, check whether
oversize thrust washers were previously installed.
i02933601
Table 77
Required Tools
Tool
Part Number
21825617
Part Description
Qty
Lifting Strap
Straight Edge
5 mm Allen Socket
21826038
POWERPART
NOTICE
Illustration 318

component life.
g01253240
Typical example
NOTICE
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.
NOTICE
has been replaced, ensure that the engine oil system
is free from debris and contaminents.
1. Clean the crankshaft and inspect the crankshaft
for wear or damage. Refer to Specications,
Crankshaft for more information. If necessary,
replace the crankshaft or recondition the
crankshaft.
2. If necessary, install the crankshaft gear. Refer to
Disassembly and Assembly, Crankshaft Gear Remove and Install.
3. If necessary, install a new crankshaft timing ring.
Timing Ring - Remove and Install.
Note: The engine should be mounted on a suitable
4. Ensure that the parent bores for the crankshaft
bearings in the cylinder block are clean. Ensure
that the threads for the bearing bolts in the cylinder
block are clean and free from damage.
Illustration 319
g01889993
6. Install upper bearings (9) to the cylinder block.

Ensure that the locating tabs for the upper
bearings are seated in the slots in the cylinder
block.
See Illustration 319. All other upper bearings have a
groove and two oil holes.
7. Lubricate upper bearings (9) with clean engine oil.
RENR9525-01
Illustration 320
147
g01254099
Illustration 322
g01253146
Illustration 323
g01253137
Typical example
8. Attach Tooling (A) and a suitable lifting device to

crankshaft (8). Carefully lift the crankshaft into
the cylinder block. The weight of the crankshaft is
approximately 30 kg (66 lb). Remove Tooling (A).
Note: Do not damage any of the nished surfaces on
the crankshaft. Do not damage the bearing.
Illustration 321
g01254100
Typical example
9. For number three bearing, ensure that thrust

washers (10) are clean and free from wear or
Lubricate thrust washers (10) with clean engine
oil. Slide the thrust washers into position between
the crankshaft and the cylinder block.
Note: The grooves in the thrust washers must be
located against the crankshaft.
10. Install lower bearings (5) into bearing caps

(4). Ensure that the locating tabs for the lower
bearings are correctly seated into the slots in
the bearing caps. For number three bearing cap,
ensure that thrust washers (7) are clean and free
from wear or damage. If necessary, replace both
the thrust washers. Lubricate thrust washers (7)
with clean engine oil. Place the thrust washers
into position on the bearing cap. Ensure that the
locating tab is correctly seated in the bearing cap.
Note: The lower bearing is a plain bearing that has
no oil holes.
11. Lubricate lower bearings (5) and lubricate the
journals of crankshaft (8) with clean engine oil.
Install bearing caps (4) to the cylinder block.
Note: Ensure the correct location and orientation of
the bearing caps. The locating tabs for the upper
and the lower bearings should be on the same side
of the engine.
148
RENR9525-01
17. If the crankshaft has been replaced or the

crankshaft has been reconditioned, inspect the
height of the piston above the cylinder block. Refer
Piston Height - Inspect for more information.
If the crankshaft has not been replaced or the
crankshaft has not been reconditioned, install the
connecting rod caps. Refer to Disassembly and
Illustration 324
g01253719
12. Lubricate the threads of bolts (3) with clean

engine oil. Lubricate the underside of the heads
of the bolts with clean engine oil.
13. Install bolts (3) to bearing caps (4). Evenly tighten
the bolts in order to pull the caps into position.
Ensure that the caps are correctly seated.
Note: Do not tap the bearing caps into position as
the bearing may be dislodged.
15. Rotate the crankshaft in order to ensure that there
is no binding.
Illustration 326
g01254102
Typical example
18. Follow Step 18.a through Step18.d in order to

install the bridge piece.
a. Ensure that the cylinder block and the bridge
piece are clean, dry and free from old sealant.
b. Install bridge piece (2) and allen head screws
(1). Tighten the allen head screws nger tight.
c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
cylinder block.
d. Use Tooling (D) in order to tighten the allen
head screws to a torque of 16 Nm (12 lb ft).
19. Install the crankshaft rear seal. Refer to
Seal - Install.
Illustration 325
g01253186
Typical example
16. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
crankshaft end play. The permissible crankshaft
end play is 0.17 to 0.41 mm (0.007 to 0.016 inch).
RENR9525-01
149
i02933611
Crankshaft Timing Ring Remove and Install

Removal Procedure
Start By:
a. Remove the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Remove .
Illustration 327
g01344593
Typical example
NOTICE
20. Apply Tooling (E) to Cavities (Y) in the bridge

piece (2). Continue to apply Tooling (E) until
sealant extrudes from Cavities (X).

component life.
Note: If the oil pan will not be installed immediately,

ensure that the face of the bridge piece and the
cylinder block are left free of sealant.
End By:
a. If necessary, install the pistons and connecting
rods. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Install.
b. If the engine has a balancer, install the balancer.
Refer to Disassembly and Assembly, Balancer Install. If the engine does not have a balancer,
install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Remove and
Install.
c. Install the front housing. Refer to Disassembly and
d. If necessary, install the cylinder head. Refer to
Disassembly and Assembly, Cylinder Head Install.
Illustration 328
e. Install the rockershaft and pushrods. Refer to

PushRod - Install.
2. Remove allen head screws (2) from crankshaft

timing ring (3). Do not reuse the allen head screws.
g01254108
1. Support crankshaft (1) on a suitable stand.
3. Carefully remove crankshaft timing ring (3) from

crankshaft (1). Do not reuse the crankshaft timing
ring.
Note: Ensure that seal surface (4) of the crankshaft
is not damaged when the crankshaft timing ring is
removed.
Note: Do not remove dowel (5) from crankshaft (1)
unless the dowel is damaged.
150
RENR9525-01
End By:
Table 78
a. Install the crankshaft. Refer to Disassembly and

Assembly, Crankshaft - Install .
Required Tools
Tool
Part Number
Part Description
Qty
4 mm Allen Socket
NOTICE
component life.
1. Support crankshaft (1) on a suitable stand.
i02933604
Crankshaft Gear - Remove and

Install
Removal Procedure
Table 79
Required Tools
2. Ensure that the ange for the crankshaft timing

ring on the crankshaft is clean and free from
damage.
Tool
Part Number
Part Description
Qty
Bearing Puller
Puller
Crossblock
Puller Leg
Start By:
a. Remove the front housing. Refer to Disassembly
b. If the engine is equipped with a balancer, remove
NOTICE
Illustration 329
g01254108
3. If dowel (5) was removed, install a new dowel to

crankshaft (1).
4. Position crankshaft timing ring (3) onto the
crankshaft with the teeth toward rear seal surface
(4). Align the hole in crankshaft timing ring (3) with
dowel (5). Carefully install crankshaft timing ring
(3) to crankshaft (1).

component life.
Note: The crankshaft gear may be a sliding t on the
crankshaft or an interference t on the crankshaft.
Note: Ensure that seal surface (4) on the crankshaft

is not damaged when the crankshaft timing ring is
installed.
5. Use Tooling (A) to install new allen head screws
(2). Tighten the allen head screws to a torque of
9 Nm (80 lb in).
RENR9525-01
151

Illustration 330
g01367358
Typical example
Illustration 332
g01367359
Typical example
2. If necessary, install a new key (3) to crankshaft (2).

Note: The crankshaft gear may be a sliding t on the
crankshaft or an interference t on the crankshaft.
Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing
or protective equipment to protect your skin.
3. If the crankshaft gear is a sliding t on the
crankshaft, align the keyway in crankshaft gear (1)
with key (3) in the crankshaft. Install crankshaft
gear (1) to crankshaft (2).
Illustration 331
g01270549
Typical example
1. If the crankshaft gear is a sliding t on the

crankshaft, remove crankshaft gear (1) from
crankshaft (2).
If the crankshaft gear is an interference t on the
crankshaft, use Tooling (A) in order to remove
crankshaft gear (1) from crankshaft (2).
2. If necessary, remove key (3) from crankshaft (2).
Note: Do not remove the key from the crankshaft
unless the key is damaged.
NOTICE
If the crankshaft gear is an interference t on the

crankshaft, heat crankshaft gear (1) in an oven to
150 50C (302 90F). Align the keyway in
crankshaft gear (1) with key (3) in the crankshaft.
Install crankshaft gear (1) to crankshaft (2).
Ensure that shoulder (4) on crankshaft gear (1) is
toward the front of the engine.
End By:
a. Install the front housing. Refer to Disassembly and

component life.
152
RENR9525-01
i02748526
Ensure that the bearing locking tabs are properly

seated in the tab grooves.
Bearing Clearance - Check
The crankshaft must be free of oil at the contact

points of Tooling (A).
Measurement Procedure
1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.
Table 80
Note: Do not allow Tooling (A) to extend over the

edge of the bearing.
Required Tools
Tool
Part
Number
Part Description
Qty
Plastic Gauge (Green)

0.025 to 0.076 mm
(0.001 to 0.003 inch)
Plastic Gauge (Red)

0.051 to 0.152 mm
(0.002 to 0.006 inch)
Plastic Gauge (Blue)

0.102 to 0.229 mm
(0.004 to 0.009 inch)
Plastic Gauge (Yellow)

0.230 to 0.510 mm
(0.009 to 0.020 inch)
2. Use the correct torque-turn specications in order

to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A)
is installed.
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 333.
NOTICE
component life.
Note: Perkins does not recommend the checking of
the actual clearances of the bearing shells particularly
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the
bearing shell or the journal surfaces. Each Perkins
bearing shell is quality checked for specic wall
thickness.
Note: The measurements should be within
specications 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, Tooling (A) is an acceptable
method. Tooling (A) 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 damage the bearing surfaces.
Illustration 333
g01152855
Typical Example
4. Remove all of Tooling (A) before you install the

bearing cap.
Note: When Tooling (A) is used, the readings can
sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specication range. Refer to Specications
Manual, Connecting Rod Bearing Journal and
Specications Manual, Main Bearing Journal for the
correct clearances.
The technician must be very careful to use Tooling (A)

correctly. The following points must be remembered:
Ensure that the backs of the bearings and the

bores are clean and dry.
RENR9525-01
153
i02933606
Crankshaft Position Sensor Remove and Install
NOTICE
component life.
Removal Procedure
NOTICE
component life.
Illustration 335
g01479572
Typical example
1. Install a new O-ring seal (5) to the groove in

position sensor (3). Lubricate the new O-ring seal
with Tooling (A).
g01479572
Illustration 334
2. Align the hole in position sensor (3) with the hole

in the cylinder block. Install the position sensor to
the cylinder block.
Typical example
1. Slide locking tab (1) into the unlocked position.
Note: Do not use bolt (4) to pull the position sensor

into position against the cylinder block.
2. Disconnect harness assembly (2) from position

sensor (3).
3. Install bolt (4). Tighten the bolt to a torque of

22 Nm (16 lb ft).
3. Remove bolt (4).
4. Connect harness assembly (2) to position sensor

(3).
4. Carefully remove position sensor (3) from the

cylinder block.
5. Slide locking tab (1) into the locked position.
Note: Do not use a lever to remove the position

sensor from the cylinder block.
i02933668
5. Remove O-ring seal (5) from position sensor (3).
Position Sensor (Fuel Injection

Pump) - Remove and Install
Table 81
Removal Procedure
Required Tools
Tool
Part Number
21820221
Part Description
POWERPART
Rubber Grease
Qty
1
NOTICE
component life.
154
RENR9525-01
g01480052
Illustration 336
Illustration 337
g01480052
Typical example
Typical example

position sensor (3). Lubricate the new O-ring seal
with Tooling (A).
2. Disconnect harness assembly (2) from position

sensor (3).
2. Remove the plug from the hole in the fuel injection

pump for the position sensor.
3. Remove bolt (4).

4. Carefully remove position sensor (3) from the fuel
injection pump.
Note: Do not use a lever to remove the position
sensor from the fuel injection pump.
3. Align the hole in position sensor (3) with the hole

in the fuel injection pump. Install the position
sensor to the fuel injection pump.
Note: Do not use bolt (4) to pull the position sensor
into position against the fuel injection pump.
5. Plug the hole for the position sensor in the fuel

injection pump with a new plug.
4. Install bolt (4). Tighten the bolt to a torque of

22 Nm (16 lb ft).
6. Remove O-ring seal (5) from position sensor (3).

5. Connect harness assembly (2) to position sensor
(3).
Table 82
Required Tools
Tool
Part Number
21820221
Part Description
POWERPART
Rubber Grease
Qty
1
NOTICE
component life.
i02933598
Coolant Temperature Sensor Remove and Install

Removal Procedure
NOTICE
component life.
RENR9525-01
155
NOTICE
mandates.
1. Drain the coolant from the cooling system, to a
level below the coolant temperature sensor, into
draining procedure.
Table 83
Required Tools
Tool
Part Number
21820221
Part Description
Qty
POWERPART
Rubber Grease
NOTICE
component life.
Illustration 339
g01480094
Typical example
Illustration 338
g01480094
Typical example

3. Disconnect harness assembly (3) from coolant
Note: The coolant temperature sensor has a two-wire
plug.
4. Use a deep socket to remove coolant temperature
sensor (1) from the cylinder head.
Note: If necessary, remove the bracket for the
harness assembly from the bypass tube.
5. Remove O-ring seal (4) from coolant temperature
sensor (1).

coolant temperature sensor (1). Lubricate the new
O-ring seal with Tooling (A).
2. Use a deep socket in order to install coolant
temperature sensor (1) to the cylinder head.
Tighten the coolant temperature sensor to a
3. Connect harness assembly (3) to coolant
Note: If necessary, install the bracket for the harness
assembly to the bypass tube.
5. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, Cooling
System Coolant Level - Check and refer to
System Coolant - Change for the correct lling
procedure.
156
RENR9525-01
Engine Oil Pressure Sensor Remove and Install
3. If necessary, remove the engine oil lter in order

to gain access to engine oil pressure sensor (1).
Engine Oil and Filter - Change.
Removal Procedure
4. If necessary, remove the dipstick tube in order

to gain access to engine oil pressure sensor (1).
Pan - Remove and Install.
NOTICE
5. Use a deep socket to remove engine oil pressure

sensor (1).

component life.
6. Remove O-ring seal (4) from engine oil pressure

sensor (1).
i02933624
NOTICE
mandates.
Note: The engine oil pressure sensor may be located
in the cylinder block, on a plate or in the engine oil
lter base. Ensure that the engine oil pressure sensor
is installed in the correct position.
Table 84
Required Tools
Tool
Part Number
21820221
Part Description
POWERPART
Rubber Grease
Qty
1
NOTICE
component life.
Note: The engine oil pressure sensor may be located
in the cylinder block, on a blanking plate or in the
engine oil lter base. Ensure that the engine oil
pressure sensor is installed in the correct position.
Illustration 340
g01480133
Typical example

2. Disconnect harness assembly (3) from engine oil
Illustration 341
g01480133
Typical example
RENR9525-01
157

engine oil pressure sensor (1). Lubricate the new
2. Use a deep socket to install engine oil pressure
sensor (1). Tighten the engine oil pressure sensor
to a torque of 10 Nm (89 lb in).
3. If necessary, install the engine oil lter. Refer to
and Filter Change.
4. If necessary, install the dipstick tube. Refer to
Disassembly and Assembly, Engine Oil Pan Remove and Install.
NOTICE
5. Connect harness assembly (3) to engine oil

7. If necessary, ll the engine oil pan to the correct
level that is indicated on the engine oil level
gauge. Refer to Operation and Maintenance
Manual, Engine Oil Level - Check.
i02933645
Fuel Pressure Sensor Remove and Install
NOTICE
mandates.
Removal Procedure
Table 85
Required Tools
Tool
Part Number
Part Description
Seal Pick
Qty
1

Illustration 342
g01459748
Typical example

2. Disconnect harness assembly (3) from fuel
3. Use a deep socket to remove fuel pressure sensor
(1) from the fuel manifold.
158
RENR9525-01
Note: After the engine has stopped, allow the

pressure to dissipate for 60 seconds before removing
the fuel pressure sensor.
4. If necessary, use Tooling (A) in order to remove
sealing washer (4) from the fuel manifold.
Note: Do not damage the seat for the washer in the
fuel manifold. Ensure that no debris enters the fuel
manifold during the removal of the sealing washer.
5. Plug the open port in the fuel manifold immediately
with a new plug.
3. Install fuel pressure sensor (1) to the fuel manifold.

Use a deep socket to tighten the fuel pressure
sensor to a torque of 5 Nm (44 lb in). Use Tooling
(B) to turn the fuel pressure sensor through an
4. Connect harness assembly (3) to fuel pressure
sensor (1).
- Prime.
i02933592
Table 86
Required Tools
Tool
Part
Number
21825607
Part Description
Qty
Angle gauge
Boost Pressure Sensor Remove and Install
Removal Procedure
NOTICE
component life.
NOTICE
component life.
Note: The boost pressure sensor may be located on
the secondary fuel lter base or in the cylinder head.
Illustration 343
g01459748
Typical example
1. Position a new sealing washer (4) onto fuel

2. Remove the plug from the fuel manifold.
Illustration 344
g01480192
Typical example

2. Disconnect harness assembly (3) from boost
RENR9525-01
159
Note: The boost pressure sensor has a three-wire

plug.
Note: If necessary, install the bracket for the harness

assembly to the bypass tube.
3. Use a deep socket to remove boost pressure

sensor (1).
3. Connect harness assembly (3) to boost pressure

sensor (1).
Note: If necessary, remove the bracket for the

harness assembly from the bypass tube.

i02933659
4. Remove O-ring seal (4) from boost pressure

sensor (1).
Inlet Air Temperature Sensor Remove and Install
Table 87
Required Tools
Tool
Part Number
21820221
Part Description
POWERPART
Rubber Grease
Qty
1
Removal Procedure
NOTICE
component life.
NOTICE
component life.
Note: The boost pressure sensor may be located on
the secondary fuel lter base or in the cylinder head.
Illustration 346
g01480292
Typical example
Illustration 345
g01480192
Typical example
1. Install a new O-ring seal (4) to the groove in boost

pressure sensor (1). Lubricate the new O-ring seal
with Tooling (A).
2. Use a deep socket to install boost pressure sensor
(1). Tighten the boost pressure sensor to a torque
of 10 Nm (89 lb in).
2. Disconnect harness assembly (3) from inlet air

Note: The inlet air temperature sensor has a two
wire plug.
3. Use a deep socket in order to remove inlet air
temperature sensor (1) from the cylinder head.
4. Remove O-ring seal (4) from inlet air temperature
sensor (1).
160
RENR9525-01
i02933653
Glow Plugs - Remove and

Install
Table 88
Required Tools
Tool
Part Number
21820221
Part Description
Qty
POWERPART
Rubber Grease
Removal Procedure
NOTICE
NOTICE

component life.

component life.
position.
Illustration 347
g01480292
Typical example
1. Install a new O-ring seal (4) to the groove in inlet

air temperature sensor (1). Lubricate the new
2. Install inlet air temperature sensor (1) to the
cylinder head. Use a deep socket in order to
tighten the inlet air temperature sensor to a torque
Illustration 348
g01245944
Typical example
3. Connect harness assembly (3) to inlet air

2. Remove nut (3) and disconnect wire (5) from bus

bar (1).

Note: The wire may be connected to either end of
the bus bar. Note the position of the wire.
3. Remove nuts (2) that secure bus bar (1) to glow
plugs (4).
4. Remove bus bar (1) from glow plugs (4).
5. Remove glow plugs (4) from the cylinder head.
RENR9525-01
161
Note: The wire may be connected to either end of

the bus bar. Ensure that the wire is installed in the
correct position.
Table 89
Required Tools
Tool
Part
Number
27610296
Part Description
Qty
Torque Wrench
5. Install nut (3) to the stud on bus bar (1). Tighten

the nut to a torque of 6 Nm (53 lb in).
position.
NOTICE
i02933675

component life.
V-Belts - Remove and Install

Belt Tensioner )
1. Ensure that the threads of the glow plugs are clean

glow plugs.
Removal Procedure
Illustration 350
g01401773
Typical example
1. If the engine is equipped with fan guards, remove

the fan guards.
Illustration 349
g01245944
Typical example
2. Loosen nut (1), bolt (2) and bolt (4). Slide the
alternator toward the engine.
2. Install glow plugs (4) into the cylinder head.

Tighten the glow plugs to a torque of 15 Nm
(132 lb in).
3. Remove V-belts (3).
3. Position bus bar (1) onto glow plugs (4). Install

nuts (2) onto the glow plugs. Use Tooling (A) in
order to tighten the nuts to a torque of 2 Nm
(17 lb in).
Note: Mark the position and direction of rotation if the

V-belts will be reused. Never replace single V-belts.
Always replace V-belts as a pair.
4. Connect wire (5) to the stud on bus bar (1).
162
RENR9525-01
i02933589
Table 90
Required Tools
Tool
Part Number
Part Description
Qty
Belt Tension Gauge
Alternator Belt - Remove and

Install
Belt Tensioner)
Removal Procedure
Table 91
Required Tools
Tool
Part Number
Part Description
Qty
Locking Pin
8mm by 85 mm
1. If the engine is equipped with fan guards, remove

the fan guards.
Illustration 351
g01401773
Typical example
1. Install V-belts (3) onto the correct pulleys.

Note: Used V-belts should be installed in the original
position and direction of rotation.
2. Adjust the tension on the V-belts by moving the
alternator away from the engine. Use Tooling (A)
in order to achieve the correct belt tension. Refer
to Specications, Belt Tension Chart for more
information. Tighten bolt (4) to a torque of 22 Nm
(16 lb ft).
Illustration 352
g01260739
Typical example
4. Tighten nut (1) to a torque of 22 Nm (16 lb ft).

5. If the engine is equipped with fan guards, install
the fan guards.
2. Install a suitable square drive tool into Hole (X) in

tensioner (3). From the front of the engine, turn
the tool in a clockwise direction.
3. Insert Tooling (A) into Hole (Y). Release the
pressure on the square drive tool.
4. Remove alternator belt (1).
Note: Mark the direction of rotation if the belt will
be reused.
5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
on Tooling (A). Remove Tooling (A) from Hole (Y).
RENR9525-01
163
6. Release the pressure on the square drive tool and

remove the tool from Hole (X).
3. Insert Tooling (A) into Hole (Y). Release the

pressure on the square drive tool.

to remove tensioner (3) from mounting bracket (2).
4. Install alternator belt (1). Ensure that the alternator

belt is centered on pulley (5). A used alternator
belt should be installed in the original direction of
rotation.
a. Remove bolt (4) that secures tensioner (3) to

mounting bracket (2).
b. Remove tensioner (3) from mounting bracket
(2).
5. From the front of the engine, turn the square drive

tool in a clockwise direction. Release the pressure
on Tooling (A). Remove Tooling (A) from Hole (Y).
Table 92
Required Tools
Tool
Part Number
Part Description
Locking Pin
8mm by 85 mm
Note: The ribs on the alternator belt must be located

into the ribs of all pulleys.
Qty
1
6. Release the pressure on the square drive tool until

the alternator belt is tensioned. Remove the tool
from Hole (X).
Note: The tensioner should be at the nominal
position.
7. If the engine is equipped with fan guards, install
the fan guards.
i02933630
Fan - Remove and Install

Removal Procedure
Start By:
Illustration 353
g01270907
a. If the engine is equipped with an automatic belt

tensioner, remove the Alternator Belt. Refer to
Disassembly and Assembly, Alternator Belt Remove and Install. If the engine is not equipped
with an automatic belt tensioner, remove the
V-Belts. Refer to Disassembly and Assembly,
V-Belts - Remove and Install.
Typical example
1. If the tensioner was previously removed, follow

Step 1.a through Step 1.c in order to install the
tensioner.
a. Align the dowel in the back of tensioner (3) with
the hole in mounting bracket (2).
b. Install tensioner (3) to mounting bracket (2).
c. Install bolt (4). Tighten the bolt to a torque of
44 Nm (32 lb ft).
2. Install a suitable square drive tool into Hole (X) in
tensioner (1). From the front of the engine, turn
the tool in a clockwise direction.
164
Illustration 354
RENR9525-01
g01270917
Illustration 355
g01270917
Typical example
Typical example
1. Remove locking nuts (1).
2. If necessary, install studs (5) to fan drive (6).
2. Remove fan (2).
3. Install fan pulley (4).
Note: Note the orientation of the fan.
4. Install fan adapter (3).
3. Remove fan adapter (3).
5. Install fan (2).
4. Remove fan pulley (4).
Note: Ensure that the fan is correctly oriented.
5. If necessary, remove studs (5) from fan drive (6).
6. Inspect the condition of locking nuts (1). If

necessary, replace the locking nuts. Install locking
nuts (1) and tighten to a torque of 22 Nm (16 lb ft).
1. Ensure that all the components are free from wear
or damage. If necessary, replace any components
End By:
a. If the engine is equipped with an automatic belt
tensioner, install the Alternator Belt. Refer to
Disassembly and Assembly, Alternator Belt Remove and Install. If the engine is not equipped
with an automatic belt tensioner, install the
V-Belts. Refer to Disassembly and Assembly,
V-Belts - Remove and Install.
i02933631
Fan Drive - Remove and Install

Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
RENR9525-01
165
i02933616
Electronic Control Module Remove and Install

Removal Procedure
Illustration 356
g00944500
NOTICE
Typical example
1. Remove bolts (1) from fan drive (2).

Note: Identify the orientation and the position of the
fan drive.
2. Remove fan drive (2).
NOTICE
mandates.
Illustration 357
g00944500
Typical example
1. Check the fan drive for wear or damage. The fan

drive is not a serviceable item. If the fan drive is
worn or damaged, replace the fan drive.

the system.
Note: Some engines do not have a fuel supply to the
electronic control module.
2. Install fan drive (2).

Note: Ensure the correct orientation of the fan drive.
44 Nm (32 lb ft).

position.
2. If the electronic control module is equipped with
a fuel supply, turn the fuel supply to the OFF
position.
End By:
a. Install the fan. Refer to Disassembly and
166
Illustration 358
RENR9525-01
g01271315
Illustration 359
g01807973
Typical example
Typical example
3. Cut cable strap (3). Unscrew bolt (6) that secures

machine wiring harness (2) to electronic control
module (5). Disconnect the machine wiring
harness from the electronic control module.
6. Remove bolts (20) and remove the assembly of

the electronic control module. Note the position of
any brackets that are secured by bolts (20). Note
the orientation of the electronic control module.
4. Cut cable straps (1), (9) and (10). Unscrew bolt

(8) that secures engine harness (7) to electronic
control module (5). Disconnect the engine harness
from the electronic control module.
7. Remove bolts (20) and remove washers (18) from

electronic control module (5). Note the position of
the ground strap for the electronic control module.
5. If the electronic control module is equipped with a

fuel supply, disconnect plastic tube assembly (4)
and plastic tube assembly (11).
8. If necessary, follow Step 8.a through Step 8.e

in order to disassemble the electronic control
module.
a. Remove isolation mounts (22) and spacers
(23).
b. Remove connectors (13). Remove O-ring seals
(12) from the connectors.
c. Remove bolt (18) and remove bracket (19) for
the engine wiring harness. Note the orientation
of the bracket.
d. Loosen bolt (16) and remove bracket (17) from
the engine wiring harness. Note the orientation
of the bracket.
e. Remove bolt (14) and remove bracket (15)
for the machine wiring harness. Note the
orientation of the bracket.
RENR9525-01
167
c. Position bracket (19) on electronic control

module (5). Ensure that the bracket is correctly
oriented. Install bolt (18). Tighten the bolt to a
torque of 9 Nm (80 lb in).
Table 93
Required Tools
Tool
Part Number
27610296
Part Description
Torque Wrench
Qty
1
1. If a replacement electronic control module is

installed, the module must be programmed with
the correct information. Refer to Troubleshooting,
Replacing the ECM and refer to Troubleshooting,
Flash Programming for the correct procedure.
2. Ensure that the electronic control module is clean
and free from damage. If necessary, replace the
electronic control module.
d. Position bracket (15) for the machine wiring

harness on electronic control module (5).
Ensure that the bracket is correctly oriented
and install bolt (14). Tighten the bolt to a torque
of 9 Nm (80 lb in).
e. Install isolation mounts (22) and spacers (23)
to electronic control module (5).
4. Install washers (21) and bolts (20) to electronic
control module (5).
Note: Ensure that the ground strap for the electronic
control module is clamped between the washer and
the appropriate bolt.
5. Install the assembly of the electronic control
module to the mounting bracket . Ensure that
any brackets that are secured by bolts (20) are
installed in the correct position. Tighten bolts (20)
Note: Ensure that the electronic control module is
correctly oriented. Ensure that the ground strap is not
strained as the bolt is tightened.
Illustration 360
g01807973
Typical example
3. If necessary, follow Step 3.a through Step 3.e in

order to assemble the electronic control module.
a. Install new O-ring seals (12) to connectors (13).
Install connectors (13) to electronic control
module (5). Tighten the connectors to a torque
b. Position bracket (17) on electronic control
module (5). Ensure that the bracket is correctly
oriented. Install torx screw (16). Tighten the
torx screw to a torque of 7 Nm (62 lb in).
Illustration 361
g01271315
Typical example
168
RENR9525-01

fuel supply, connect plastic tube assembly (4) and
tube assembly (11) to electronic control module
(5).
7. Connect engine wiring harness (7) to electronic
control module (5). Use Tooling (A) to tighten bolt
(8) to a torque of 5 Nm (44 lb in). If the engine is
equipped with a diagnostic connection, install the
diagnostic connection to the support clip.
Note: Care must be taken in order to avoid damage to
the connector pins during installation of the harness.
8. Position the assembly of the engine wiring harness
onto bracket (15), bracket (17) and bracket (19).
Use new cable straps (1), (9) and (10) in order to
secure the harness assembly to the brackets.
9. Connect machine wiring harness (2) to electronic
control module (5). Use Tooling (A) to tighten bolt
(6) to a torque of 5 Nm (44 lb in).
Illustration 362
g01254468
Typical example
1. Remove plastic tube assembly (3) and assembly

(4) from clips (5).
Note: Care must be taken in order to avoid damage to

the connector pins during installation of the harness.
2. Cut the cable strap and position the engine wiring

harness away from mounting bracket (2).
10. Use a new cable strap (3) in order to secure the

machine wiring harness (2).
3. Remove bolts (1) and remove mounting bracket


fuel supply, turn the fuel supply to ON position.
4. If necessary, remove clips (5) from mounting

bracket (2).

position.

fuel supply, remove the air from the fuel system.
Fuel System - Prime.
1. Ensure that the mounting bracket for the electronic

control module is clean and free from damage. If
necessary, replace the mounting bracket.
i02933614
ECM Mounting Bracket Remove and Install

Removal Procedure
Start By:
a. Remove the electronic control module. Refer to
RENR9525-01
169
NOTICE
component life.
position.
2. Make temporary identication marks on the
connections of the harness assembly.
Illustration 363
g01254468
Typical example
2. If necessary, install clips (5) to mounting bracket

(2).
3. Position mounting bracket (2) against the cylinder
head. Install bolts (1). Tighten the bolts to a torque
4. Position the engine wiring harness against
mounting bracket (2). Secure the engine wiring
harness with a new cable strap.
Illustration 364
5. Install plastic tube assembly (3) and assembly (4)

to clips (5).
g01255718
Typical Example
3. Disconnect the harness assembly from alternator

(4).
End By:
a. Install the electronic control module. Refer to
i02933588
Alternator - Remove
Belt Tensioner)
Removal Procedure
4. Remove bolt (6) from alternator (4).

5. Remove nut (1) and washer (2). Remove bolt (5)
from alternator (4). Remove alternator (4) from
alternator bracket (3).
6. If necessary, remove pulley (8) from alternator (4).
Follow Step 6.a and Step 6.b for the method in
order to remove the pulley from the alternator.
Note: This method may not be suitable for some
congurations of pulley.
a. Hold the shaft of alternator (4) with an allen
wrench. Use a cranked ring spanner (box
wrench) in order to loosen nut (7).
Start By:
a. Remove the V-belts. Refer to Disassembly and
Assembly, V-belts - Remove and Install.
b. Remove nut (7) and pulley (8) from alternator

(4).
170
RENR9525-01
i02933586
Alternator - Remove
Belt Tensioner)
Removal Procedure
b. Remove nut (7) and pulley (8) from alternator

(3).
i02933587
Alternator - Install
Belt Tensioner)
Start By:
a. Remove the alternator belt. Refer to Disassembly
Install.
NOTICE
component life.
position.
connections of the harness assembly.
Illustration 366
g01263045
Typical example
1. If necessary, install the pulley to the alternator.

Follow Step 1.a and Step 1.b in order to install the
pulley to the alternator.
Illustration 365
g01271317
Typical example
3. Disconnect the harness assembly from alternator

(3).
4. Remove bolt (5) from alternator (3).
5. Remove nut (1) and washer (2). Remove bolt (6)
from alternator (3). Remove the alternator from
alternator bracket (4).
to remove pulley (8) from alternator (1).
a. Hold the shaft of alternator (3) with an allen
wrench) in order to loosen nut (7).
Note: This method may not be suitable for some

congurations of pulley.
a. Install pulley (8) and nut (7) to the shaft of
alternator (4).
b. Hold the shaft of the alternator with an allen
wrench) in order to tighten nut (7). Tighten the
nut to a torque of 80 Nm (59 lb ft).
2. Install alternator (4) to bracket (3) and install bolt
(5) to alternator (4).
3. Install washer (2) and nut (1) to bolt (5) nger tight.
4. Install bolt (6) through adjusting link (9) to
alternator (4) nger tight.
RENR9525-01
171
5. Install the V-belts. Refer to Disassembly and

assembly, V-belts - Remove and Install for the
correct procedure.
6. Tighten nut (1) and bolt (6) to a torque of 22 Nm
(16 lb ft).
2. Position alternator (3) on alternator mounting

bracket (4).
3. Install bolt (6) to alternator (3). Install washer (2)
and nut (1) to bolt (6).
4. Install bolt (5) to alternator (3).
7. Connect the wiring harness assembly to alternator

(4).
position.
i02933585
Alternator - Install
Belt Tensioner)
5. Tighten nut (1) and bolt (5) to a torque of 22 Nm

(16 lb ft).
6. Connect the wiring harness assembly to alternator
(3).
7. Install the alternator belt. Refer to Disassembly
Install.
position.
i02933615
Electric Starting Motor Remove and Install
NOTICE
component life.
Removal Procedure
Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative () battery terminal. Completely tape all metal surfaces of the
disconnected battery cable end in order to prevent
contact with other metal surfaces which could activate the engine electrical system.
Illustration 367
g01271317
Place a Do Not Operate tag at the Start/Stop switch

location to inform personnel that the equipment is
being worked on.
Typical example
1. If necessary, install pulley (8) and nut (7) to

alternator (3). Hold the shaft of the alternator with
an allen wrench. Use a cranked ring spanner (box
wrench) in order to tighten nut (7).
Note: Different types of alternator have different
sizes of nut. Ensure that the correct torque value is
used for the nut.
Tighten M16 and M17 nuts to a torque of 80 Nm
(59 lb ft). Tighten 5/8 inch - 18 UNF nuts to a

position.
2. If necessary, remove the hose for the crankcase
breather. Refer to Disassembly and Assembly,
Crankcase Breather - Remove and Install.
harness assemblies that are connected to the
electric starting motor and to the solenoid.
172
RENR9525-01
5. If necessary, install the hose for the crankcase

breather. Refer to Disassembly and Assembly,
Crankcase Breather - Remove and Install.
position.
i02933584
Air Compressor - Remove and

Install
Illustration 368
g01261155
Removal Procedure
Typical example
4. Disconnect the harness assemblies from the

electric starting motor and from the solenoid.
5. Remove nuts (3) from electric starting motor (1).
Note: Support the weight of the electric starting
motor as the nuts are removed.
Table 94
Required Tools
Tool
Part Number
Part Description
Qty
A(1)
21825576
27610291
27610289
Gear
27610211
Puller (Three Leg)
A(2)
6. Remove electric starting motor (1).

7. If necessary, remove studs (2).
(1)
(2)


NOTICE
mandates.
Illustration 369
g01261155
Typical example
1. If necessary, install studs (2).

2. Align electric starting motor (1) to studs (2). Install
the electric starting motor.
3. Install nuts (3).
Tighten M10 nuts to a torque of 44 Nm (32 lb ft).
Tighten M12 nuts to a torque of 78 Nm (57 lb ft).
NOTICE
component life.
hose assemblies and on all tube assemblies for
installation purposes. Plug all hose assemblies and
tube assemblies. This helps to prevent uid loss and
this helps to keep contaminants from entering the
system.
4. Connect the harness assemblies to the electric

starting motor and the solenoid.
RENR9525-01
173
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
1. Release the pressure from the air system.
draining procedure.
3. Remove the front cover. Refer to Disassembly and
4. If the engine is equipped with a hydraulic pump
on the rear of the air compressor, remove the
hydraulic pump.
Note: The air compressor must be timed with the
engine in order to minimize engine vibration.
Illustration 371
g01250794
Typical example
7. Disconnect coolant hoses (1) and (2) from air

compressor (4).
8. Disconnect the air lines from ports (3) and (5).
9. Remove tube assembly (7) from air compressor
(4) and from the cylinder block.
10. Remove bolts (8) and (10) from support bracket
(9) and remove the support bracket.
Illustration 370
g01272266
Typical example
6. Install Tooling (B) through Hole (X) in the front

housing. Use Tooling (B) in order to lock the
crankshaft.
174
Illustration 372
RENR9525-01
g01250816
g01250889
Illustration 373
Typical example
Typical example
11. Support air compressor (4). Remove nuts (13)

and remove the air compressor from front housing
(6).
12. Remove O-ring seal (18) from air compressor (4).

13. If necessary, remove bolts (15) and remove plate
(14). Remove O-ring seal (11) from plate (14).
14. If necessary, remove nut (17) and remove
the spring washer. Use Tooling (C) in order to
remove gear (16) from the crankshaft of the air
compressor.
Table 95
Required Tools
Tool
Part Number
Part Description
Qty
27610211
21826051
POWERPART
High Strength Retainer
21820221
POWERPART
Rubber Grease
NOTICE
component life.
RENR9525-01
175
NOTICE

Note: The air compressor must be timed with the
engine in order to minimize engine vibration.

mandates.
Illustration 375
g01272266
Typical example
4. Ensure that Tooling (B) is installed in Hole (X) in

Illustration 374
g01250889
Typical example
1. If necessary, follow Step 1.a through Step 1.b in

order to install the gear to the air compressor.
Illustration 376
g01250968
Typical air compressor with a SAE drive
a. Ensure that the shaft of air compressor (4) is

clean and dry. Ensure that gear (16) is clean
and free from damage.
b. Install gear (16) and a new spring washer to
the shaft of the air compressor.
c. Apply Tooling (D) to the threads of the shaft.
Install nut (17) to the shaft of air compressor
(4). Tighten the nut to a torque of 120 Nm
(89 lb ft).
2. Install the O-ring seal to air compressor (4). Use
Tooling (E) in order to lubricate the O-ring seal.
Illustration 377
g01251223
Typical air compressor with a DIN drive
176
RENR9525-01
5. Rotate the crankshaft of the air compressor until

timing Mark (X) is aligned with timing mark A4
on the rear face of air compressor (4). Refer to
Illustration 376 for air compressors with a SAE
drive. Refer to Illustration 377 for air compressors
with a DIN drive.
Illustration 379
g01250794
Typical example
9. Position support bracket (9) onto air compressor

(4). Install bolts (8) nger tight.
Illustration 378
g01250816
Typical example
6. Align air compressor (4) with studs (12). Install the

air compressor to the front housing. If necessary,
rotate the crankshaft of the air compressor in a
clockwise direction in order to align the gears.
Note: Ensure that timing Mark (X) is aligned with
timing mark A4. Refer to Illustration 376 for air
compressors with a SAE drive. Refer to Illustration
377 for air compressors with a DIN drive.
7. Install nuts (13). Tighten the nuts to a torque of
78 Nm (58 lb ft).
8. If necessary, follow Step 8.a through Step 8.c in
order to install cover (14).
a. Install a new O-ring seal (11) to cover (14). Use
Tooling (E) in order to lubricate the O-ring seal.
b. Install cover (14) to air compressor (4).
c. Install bolts (15). Tighten the bolts to a torque
of 13 Nm (9.5 lb ft).

Tighten bolts (10) to a torque 22 Nm (16 lb ft).
Note: Ensure that the air compressor is not stressed
as the bolts are tightened.
12. Install tube assembly (7) to air compressor (4)
and to the cylinder block. Tighten the nuts to a
torque of 9 Nm (80 lb in).
13. Remove Tooling (B) from Hole (X) in the front
housing.
14. Install the front cover. Refer to Disassembly and
15. If the engine is equipped with a hydraulic pump
on the rear of the air compressor, install the
hydraulic pump.
16. Connect the air lines to ports (3) and (5) in the
air compressor.
17. Connect coolant hoses (1) and (2) to air
compressor (4).
RENR9525-01
177
18. Fill the cooling system with coolant to the correct

level. Refer to Operation and Maintenance
Manual, Cooling System Coolant - Change for
i02933676
Vacuum Pump - Remove and

Install
NOTICE
component life.
Removal Procedure
NOTICE
component life.
hose assemblies and on all tube assemblies for
installation purposes. Plug all hose assemblies and
tube assemblies. This helps to prevent uid loss and
this helps to keep contaminants from entering the
system.
Illustration 381
g01254510
Typical example
1. Ensure that the vacuum pump is clean and free

from damage. If necessary, replace the vacuum
pump.
2. Clean the surfaces on the front housing.
3. Install a new gasket to vacuum pump (1).
4. Install vacuum pump (1) to the front housing. If
necessary, rotate the shaft of the vacuum pump in
order to align the gears.
5. Install bolts (2).
Illustration 380
g01254510
Typical example
1. Remove tube assembly (4) from vacuum pump

(1) and from the cylinder block.
6. Connect the vacuum line to connector (3).

7. Install tube assembly (4) to vacuum pump (1) and
to the cylinder block. Tighten the nuts on the tube
assembly to a torque of 9 Nm (80 lb in).
2. Disconnect the vacuum line from connector (3) on

the vacuum pump.
3. Remove bolts (2). Remove vacuum pump (1) from
the front housing.
4. Remove the gasket.
178
Index Section
RENR9525-01
Index
A
Accessory Drive - Assemble.................................. 92
Assembly Procedure.......................................... 92
Accessory Drive - Disassemble............................. 92
Disassembly Procedure ..................................... 92
Accessory Drive - Install ........................................ 93
Installation Procedure ........................................ 93
Accessory Drive - Remove .................................... 91
Removal Procedure ........................................... 91
Air Compressor - Remove and Install.................. 172
Installation Procedure ...................................... 174
Removal Procedure ......................................... 172
Alternator - Install (Engines With an Automatic Belt
Tensioner) .......................................................... 171
Alternator - Install (Engines Without an Automatic
Belt Tensioner)................................................... 170
Alternator - Remove (Engines With an Automatic Belt
Tensioner) .......................................................... 170
Alternator - Remove (Engines Without an Automatic
Belt Tensioner)................................................... 169
Alternator Belt - Remove and Install (Engines With
an Automatic Belt Tensioner)............................. 162
B
Balancer - Install..................................................
Assembly Procedure........................................
Installation Procedure ......................................
Balancer - Remove..............................................
Disassembly Procedure ...................................
Removal Procedure .........................................
Bearing Clearance - Check .................................
Measurement Procedure .................................
Boost Pressure Sensor - Remove and Install......
126
126
127
124
126
124
152
152
158
159
158
C
Camshaft - Remove and Install ............................ 113
Installation Procedure ....................................... 114
Removal Procedure .......................................... 113
Camshaft Bearings - Remove and Install ............. 117
Camshaft Gear - Remove and Install ................... 115
Connecting Rod Bearings - Install (Connecting rods
in position) ......................................................... 137
Connecting Rod Bearings - Remove (Connecting

rods in position) ................................................. 136
Coolant Temperature Sensor - Remove and
Install ................................................................. 154
Crankcase Breather - Remove and Install (Filtered
Breather).............................................................. 94
Crankcase Breather - Remove and Install (Unltered
Breather).............................................................. 96
Crankshaft - Install............................................... 146
Crankshaft - Remove........................................... 143
Crankshaft Front Seal - Remove and Install.......... 72
Crankshaft Gear - Remove and Install ................ 150
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position)...................................... 139
Crankshaft Position Sensor - Remove and
Install ................................................................. 153
With an Automatic Belt Tensioner)....................... 70
Without an Automatic Belt Tensioner).................. 71
Crankshaft Rear Seal - Install................................ 67
Crankshaft Rear Seal - Remove............................ 66
Crankshaft Timing Ring - Remove and Install ..... 149
Cylinder Head - Install ......................................... 109
Cylinder Head - Remove ..................................... 105
D
Disassembly and Assembly Section........................ 5
RENR9525-01
179
Index Section
ECM Mounting Bracket - Remove and Install...... 168

Electric Starting Motor - Remove and Install ....... 171
Electronic Control Module - Remove and Install.. 165
Electronic Unit Injector - Install .............................. 30
Alternative Installation Procedure ...................... 33
Electronic Unit Injector - Remove .......................... 26
Alternative Removal Procedure ......................... 29
Engine Oil Cooler - Install...................................... 55
Engine Oil Cooler - Remove.................................. 54
Engine Oil Filter Base - Remove and Install.......... 52
Engine Oil Pan - Remove and Install (Aluminum and
Pressed Steel Oil Pans)...................................... 119
Engine Oil Pan - Remove and Install (Cast Iron Oil
Pan) ................................................................... 121
Engine Oil Pressure Sensor - Remove and
Install ................................................................. 156
Engine Oil Pump - Remove and Install (Engines
Without a Balancer Unit)...................................... 58
with a Balancer Unit)............................................ 56
Without a Balancer Unit)...................................... 57
Exhaust Elbow - Remove and Install..................... 45
Exhaust Manifold - Remove and Install (Side
Mounted Exhaust Manifold) ................................. 44
Installation Procedure (Side Mounted Exhaust
Manifold) .......................................................... 45
Exhaust Manifold - Remove and Install (Top Mounted
Exhaust Manifold) ................................................ 42
Installation Procedure (Top Mounted Exhaust
Manifold) .......................................................... 43
Fan - Remove and Install .................................... 163

Fan Drive - Remove and Install ........................... 164
Flywheel - Install.................................................... 65
Flywheel - Remove................................................ 64
Flywheel Housing - Remove and Install ................ 68
Front Cover - Remove and Install.......................... 73
Fuel Filter Base - Remove and Install (Secondary
Fuel Filter).............................................................. 8
Installation Procedure .......................................... 9
Removal Procedure ............................................. 8
Fuel Injection Lines - Install ................................... 17
Fuel Injection Lines - Remove ............................... 16
Fuel Injection Pump - Install .................................. 21
Fuel Injection Pump - Remove .............................. 18
Fuel Injection Pump Gear - Install ......................... 25
Fuel Injection Pump Gear - Remove ..................... 23
Fuel Manifold (Rail) - Remove and Install ............. 13
Fuel Pressure Sensor - Remove and Install........ 157
Fuel Priming Pump - Remove and Install (Electric
Fuel Priming Pump) ............................................... 5
Fuel Priming Pump - Remove and Install (Manual
Priming Pump) ....................................................... 6
Fuel Transfer Pump - Install ................................... 11
Installation Procedure ......................................... 11
Fuel Transfer Pump - Remove ................................ 9
G
Gear Group (Front) - Remove and Install.............. 75
Glow Plugs - Remove and Install ........................ 160
180
Index Section
RENR9525-01
H
Housing (Front) - Install .........................................
Installation Procedure ........................................
Housing (Front) - Remove .....................................
Removal Procedure ...........................................
89
89
87
87
I
Idler Gear - Install ...................................... 82, 8485
Installation Procedure (Heavy-Duty Idler Gear).. 82
Installation Procedure (Latest Heavy-Duty Idler
Gear) ................................................................ 85
Installation Procedure (Standard Idler Gear) ..... 84
Idler Gear - Remove .................................. 7879, 81
Removal Procedure (Early Heavy-Duty Idler
Gear) ................................................................ 78
Removal Procedure (Latest Heavy-Duty Idler
Gear) ................................................................ 81
Removal Procedure (Standard Idler Gear) ........ 79
Important Safety Information ................................... 2
Inlet Air Temperature Sensor - Remove and
Install ................................................................. 159
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 46
Inlet and Exhaust Valves - Remove and Install ..... 50
L
Lifter Group - Remove and Install......................... 112
P
Piston Cooling Jets - Remove and Install............ 129
Pistons and Connecting Rods - Assemble .......... 132
Assembly Procedure........................................ 132
Pistons and Connecting Rods - Disassemble ..... 131
Disassembly Procedure ................................... 131
Pistons and Connecting Rods - Install................. 134
Pistons and Connecting Rods - Remove............. 130
Position Sensor (Fuel Injection Pump) - Remove and
Install ................................................................. 153
Rocker Shaft - Assemble.....................................

Assembly Procedure........................................
Rocker Shaft - Disassemble ................................
Disassembly Procedure ...................................
Rocker Shaft and Pushrod - Install......................
Rocker Shaft and Pushrod - Remove..................
103
103
102
102
104
104
101
101
T
Table of Contents..................................................... 3
Turbocharger - Install (Side Mounted
Turbochargers) .................................................... 40
Turbocharger - Install (Top Mounted Turbocharger
)............................................................................ 38
Turbocharger - Remove (Side Mounted
Turbochargers) .................................................... 37
Turbocharger - Remove (Top Mounted Turbocharger
)............................................................................ 35
V
V-Belts - Remove and Install (Engines Without an
Automatic Belt Tensioner )................................. 161
Vacuum Pump - Remove and Install ................... 177
Valve Mechanism Cover - Remove and Install...... 96
Valve Mechanism Cover Base - Remove and
Install ................................................................... 98
W
Wastegate Solenoid - Remove and Install ............
Water Pump - Install ..............................................
Water Pump - Remove ..........................................
Water Temperature Regulator - Remove and
Install ...................................................................
41
42
41
62
62
61
61
63
64
63
RENR9525-01
181
Index Section
182
Index Section
RENR9525-01
RENR9525-01
183
Index Section
2009 Perkins Engines Company Limited

All Rights Reserved
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1104D Perkins NJ

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RENR9525-01

This document is printed from SPI. Not for RESALE

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

This document is printed from SPI. Not for RESALE

Front Cover - Remove and Install ......................... 73

This document is printed from SPI. Not for RESALE

Inlet Air Temperature Sensor - Remove and

This document is printed from SPI. Not for RESALE

Disassembly and Assembly

Fuel Priming Pump - Remove

4. Disconnect plastic tube assembly (1) and plastic

3. Disconnect harness assembly (3) from electric

Note: If the tube assemblies have quick t

This document is printed from SPI. Not for RESALE

1. Ensure that the electric priming pump is clean and

Fuel Priming Pump - Remove

2. Position electric priming pump (4) on the mounting

6. Turn the fuel supply to the ON position.

This document is printed from SPI. Not for RESALE

1. Ensure that the fuel priming pump is clean and

1. Turn the fuel supply to the OFF position.

6. If necessary, follow Step 6.a through Step 6.c in

2. If necessary, follow Step 2.a through Step 2.d in

b. Remove plugs (5) from fuel priming pump (4).

a. Install new O-ring seals (3) to connectors (2)

c. Remove O-ring seals (3) from connectors (2)

b. Install connectors (2) to fuel priming pump (4).

This document is printed from SPI. Not for RESALE

3. Position fuel priming pump (4) on the mounting

Fuel Filter Base - Remove and

3. Disconnect plastic tube assemblies (3), (5) and (6)

This document is printed from SPI. Not for RESALE

6. Remove bolts (2) from fuel lter base (1). Remove

4. If necessary, install the boost pressure sensor.

6. Remove plugs from plastic tube assemblies (3),

Note: If the tube assemblies have quick t

1. Ensure that the fuel lter base is clean and free

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

7. Turn the fuel supply to the ON position.

Fuel Transfer Pump - Remove

2. Position fuel lter base (1) onto the cylinder head.

This document is printed from SPI. Not for RESALE

5. Remove the plastic tube assembly from outlet

Note: Put identication marks on all hoses, on all

7. Loosen banjo bolt (3) and banjo bolt (8). Remove

9. Remove banjo bolt (8) and sealing washers (10)

3. If necessary, disconnect the harness assembly

10. Use an allen wrench with a ball end in order

Note: If the tube assembly has quick t connections,

This document is printed from SPI. Not for RESALE

Fuel Transfer Pump - Install

11. Remove the fuel transfer pump from fuel injection

12. Remove O-ring seal (12) from fuel transfer pump

2. Install a new O-ring seal (12) for fuel transfer

This document is printed from SPI. Not for RESALE

6. Install banjo bolt (8) and new sealing washers (10)

9. If necessary, install a new O-ring seal to inlet

3. Align fuel transfer pump (4) with dowels (11) in