Uenr4544 00

UENR4544 (en-us)
January 2016
Disassembly and Assembly

4008-30 Industrial Engine
SD8 (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
UENR4544 3
Table of Contents
Table of Contents Valve Mechanism Cover - Remove and Install

(Rocker Box Cover) ......................................... 144
Valve Mechanism Cover Base - Remove and Install
Disassembly and Assembly Section (Rocker Box) ................................................... 145
Rocker Arm and Shaft - Remove ........................ 147
Fuel Transfer Pump - Remove and Install (Lift Rocker Arm - Disassemble................................. 148
Pump) ................................................................4 Rocker Arm - Assemble ..................................... 149
Fuel Manifold (Rail) - Remove and Install (Engine Oil Rocker Arm and Shaft - Install ............................ 151
and Fuel Rail)......................................................5 Cylinder Head - Remove.................................... 152
Governor - Remove (Electronic Control Unit)......... 11 Cylinder Head - Install ....................................... 155
Governor - Install (Electronic Control Unit) ............12 Lifter Group - Remove (Cam Followers) .............. 158
Governor Actuator - Remove and Install ...............13 Lifter Group - Disassemble (Cam Followers) ....... 158
Fuel Injection Control Linkage - Remove ..............20 Lifter Group - Assemble (Cam Followers)............ 160
Fuel Injection Control Linkage - Install ..................25 Lifter Group - Install (Cam Followers).................. 161
Fuel Injector - Remove ........................................30 Camshaft - Remove .......................................... 162
Fuel Injector - Install ...........................................31 Camshaft - Install .............................................. 163
Fuel Injector Sleeve - Remove .............................33 Camshaft Bearings - Remove ............................ 164
Fuel Injector Sleeve - Install .................................34 Camshaft Bearings - Install ................................ 165
Air Cleaner - Remove and Install ..........................37 Engine Oil Pan - Remove .................................. 166
Turbocharger - Remove.......................................40 Engine Oil Pan - Install ..................................... 168
Turbocharger - Install ..........................................45 Cylinder Liner - Remove .................................... 170
Air Lines - Remove and Install (Turbocharger Cylinder Liner - Install ........................................ 171
Compressor Outlet Tube Assemblies) .................53 Piston Cooling Jets - Remove and Install ............ 173
Exhaust Manifold - Remove and Install ................63 Pistons and Connecting Rods - Remove ............. 175
Exhaust Elbow - Remove and Install ....................73 Pistons and Connecting Rods - Disassemble ...... 177
Inlet Manifold - Remove ......................................76 Pistons and Connecting Rods - Assemble........... 178
Inlet Manifold - Install ..........................................79 Pistons and Connecting Rods - Install................. 181
Inlet and Exhaust Valves - Remove and Install.......82 Crankshaft Main Bearings - Remove and Install .. 184
Inlet and Exhaust Valve Guides - Remove and Crankshaft - Remove......................................... 186
Install ...............................................................85 Crankshaft - Install ............................................ 187
Engine Oil Filter Base - Remove...........................86 Crankshaft Gear - Remove and Install ................ 190
Engine Oil Filter Base - Install ..............................88 Bearing Clearance - Check ................................ 191
Engine Oil Cooler - Remove.................................90 Coolant Temperature Switch - Remove and
Engine Oil Cooler - Disassemble .........................93 Install ............................................................. 192
Engine Oil Cooler - Assemble ..............................94 Engine Oil Pressure Switch - Remove and Install 193
Engine Oil Cooler - Install ....................................95 Engine Oil Pressure Switch - Remove and Install
Engine Oil Relief Valve - Remove and Install (Engine (Alternator Warning Lamp) ............................... 194
Oil Pressure Regulator)......................................98 Temperature Sensor (Exhaust) - Remove and Install
Engine Oil Relief Valve - Remove and Install (Engine (Exhaust Temperature Thermocouples)............. 195
Oil Cooler) ...................................................... 100 Engine Speed Sensor - Remove and Install
Engine Oil Pump - Remove ................................ 102 (Overspeed Sensor) ........................................ 196
Engine Oil Pump - Disassemble ......................... 104 Engine Speed Sensor - Remove and Install (Engine
Engine Oil Pump - Assemble.............................. 105 Speed for Governor Control) ............................ 198
Engine Oil Pump - Install.................................... 107 Boost Pressure Sensor - Remove and Install....... 199
Water Pump - Remove ...................................... 110 V-Belts - Remove and Install (Fan Drive Belts)..... 200
Water Pump - Disassemble ............................... 111 Alternator Belt - Remove and Install ................... 203
Water Pump - Assemble ................................... 112 Alternator - Remove and Install (Battery Charging
Water Pump - Install .......................................... 113 Alternator)....................................................... 204
Water Temperature Regulator Housing - Remove and Alternator - Remove and Install (Battery Charging
Install (Thermostat Housing)............................. 114 Alternator Drive) .............................................. 207
Engine Support (Front) - Remove and Install (Back Electric Starting Motor - Remove and Install ....... 212
plate) .............................................................. 117
Flywheel - Remove............................................ 119 Index Section
Flywheel - Install ............................................... 121
Crankshaft Rear Seal - Remove and Install ......... 123 Index................................................................ 215
Flywheel Housing - Remove and Install .............. 124
Vibration Damper and Pulley - Remove and Install
(Twin Vibration Dampers)................................. 127
Crankshaft Front Seal - Remove and Install......... 132
Gear Group (Front) - Remove ............................ 133
Gear Group (Front) - Install ................................ 134
Housing (Front) - Remove (Timing Case) ............ 137
Housing (Front) - Install (Timing Case)................ 138
Crankcase Breather - Remove and Install .......... 141
4 UENR4544
Disassembly and Assembly Section
Disassembly and
Assembly Section
i06513480
Fuel Transfer Pump - Remove

and Install
(Lift Pump)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 1 g01429930
NOTICE
Care must be taken to ensure that fluids are con- 3. Disconnect tube assembly (3) from fuel lift pump
tained during performance of inspection, mainte- (5). Cap all open tube assembly and connection.
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- 4. Disconnect tube assembly (4) from fuel lift pump
ers before opening any compartment or disassem- (5). Cap all open tube assembly and connection.
bling any component containing fluids.
5. Remove nuts (1) and remove fuel lift pump (5)
Dispose of all fluids according to local regulations from the engine oil pump.
and mandates.
6. Remove gasket (2) (not shown).
1. Turn the fuel supply to the “OFF” position. 7. If necessary, remove fuel priming pump (6) from
fuel lift pump (5). Refer to Disassembly and
2. Switch OFF battery charger (if installed) or the Assembly, “Fuel Priming Pump - Remove and
disconnect the mains supply and disconnect the Install” for the correct procedure.
negative lead from the batteries.
Installation Procedure
NOTICE
component life.
1. Ensure that the gasket surfaces of the fuel lift

pump and the engine oil pump are clean and free
from damage. Inspect the seal and inspect the
drive for the fuel lift pump for wear or damage.
UENR4544 5
11. Remove the air from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.
i06541716
Fuel Manifold (Rail) - Remove

and Install
(Engine Oil and Fuel Rail)
Removal Procedure
NOTICE
component life.
NOTICE
2. If necessary, install fuel priming pump (6) to fuel lift Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
pump (5). Refer to Disassembly and Assembly, nance, testing, adjusting and repair of the product.
“Fuel Priming Pump - Remove and Install” for the Be prepared to collect the fluid with suitable contain-
correct procedure. ers before opening any compartment or disassem-
3. Position a new gasket (2) (not shown) onto the
engine oil pump. Lubricate the drive for the fuel lift Dispose of all fluids according to local regulations
pump and the seal in the engine oil pump with and mandates.
clean engine oil.
4. Install fuel lift pump (5) on the engine oil pump. 1. Switch OFF battery charger (if installed) or the
Install nuts (1). Tighten the nuts to a torque of disconnect the mains supply and disconnect the
25 N·m (18 lb ft). negative lead from the batteries.
2. Turn the fuel supply to the OFF position.
Note: Ensure that the shaft of the fuel lift pump is
aligned with the drive in the rear of engine oil pump.
5. Remove the cap from tube assembly (3) and

connection. Connect the tube assembly from fuel
lift pump (5).
6. Remove the cap from tube assembly (4) and
connection. Connect the tube assembly from fuel
lift pump (5).
7. Tighten the tube nut for tube assembly (4) to a
torque of 68 N·m (50 lb ft).
8. Tighten the tube nut for tube assembly (3) to a
9. Turn the fuel supply to the “ON” position.
10. Switch ON battery charger (if installed) or the
connect the mains supply and connect the
negative lead to the batteries.
6 UENR4544
5. Disconnect tube assembly (5), tube assembly (6),

and tube assembly (7) from engine oil rail (1) and
valve mechanism cover base (2).
6. Repeat Step 3 through Step 5 to remove the
remaining tube assembly (5), tube assembly (6),
and tube assembly (7) from engine oil rail (1) and
valve mechanism cover base (2).
7. Remove nut and bolts (14) from clamps (15). If
necessary, follow Step 7 to remove remaining nuts
and bolt and clamps.
8. Use a suitable tool to hold connection (10) and
loosen tube nut (9). Disconnect tube assembly (8)
from the connection.
loosen tube nut (12). Disconnect tube assembly
(11) from the connection.
Typical example

loosen tube nut (18). Disconnect hose assembly
(19) from the connection.
11. Remove bolts (16) from engine oil rail (1).
Remove the engine oil rail from the cylinder heads
3. Remove bolt (3) from clip (4).

4. Use a suitable tool to hold connections for tube
assembly (5), tube assembly (6), and tube
assembly (7).
UENR4544 7
h. Make temporary marks on bracket (26) and

engine oil rail (1) for installation purposes.
i. Remove nuts and bolts (24) and remove

bracket (26) from engine oil rail (1).
j. If necessary, repeat Step 12.h through Step

12.j to remove remaining bracket (26) from
engine oil rail (1).
Table 1
Required Tools
Tool Part Number Part Description Qty
Loctite 542 Thread and Nut

A - 1
Lock
NOTICE
component life.
1. Ensure that all components for engine oil rail and

fuel rail are free from wear, damage, or restriction.
Replace any component that is worn, damaged, or
restricted.
Front and rear sections of engine oil rail and fuel rail
12. Follow Step 12.a through Step 12.j to

disassembly the engine oil rail.
a. Remove connections (21) from engine oil rail

(1).
b. Remove sealing washers (20) (not shown)

from connections (21).
c. Repeat Step 12.a through Step 12.b to

remove remaining connections (21) from
engine oil rail (1).
d. Remove connection (17) from engine oil rail

(1).
e. Remove sealing washers (20) (not shown).
f. Remove connection (10) and connection (13)

from engine oil rail (1).
g. Remove sealing washer (23) (not shown) and

sealing washer (25).
8 UENR4544
g. Install new sealing washers (20) (not shown)

to connections (21).
h. Apply Tooling (A) to the threads of

connections (21). Install the connection to
engine oil rail (1). Tighten the connection to a
torque of 15 N·m (133 lb in).
i. If necessary, repeat Step 2.g through Step 2.k

to install remaining connections (21) to engine
oil rail (1).
j. Install a new seal washer (22) to connection

(17).
k. Apply Tooling (A) to the threads of connection

(17) and install the connection Tighten the
connection to a torque of 35 N·m (26 lb ft).
Front and rear sections of engine oil rail and fuel rail
2. Follow Step 2.a through Step 2.k to disassembly

the engine oil rail.
a. Position bracket (26) onto engine oil rail (1).

Ensure that the bracket is correctly orientated
on the engine oil rail.
b. Install nuts and bolts (24) to bracket (26). 3. Position engine oil rail (1) onto the cylinder heads.
Hand tighten the nuts and bolts. Install bolts (16) hand tight.
4. Connect hose assembly (19) to connection (17).
c. If necessary, repeat Step 2.a through Step 2.b Use a suitable tool to hold the connection and
to install remaining bracket (26) to engine oil tighten tube nut (18) to a torque of 35 N·m
rail (1). (26 lb ft). Ensure that connection(17) is not moved
d. Install a new sealing washer (23) (not shown) as the tube nut (18) is tightened.
and a new sealing washer (25) to connection Note: Ensure that the hose assembly is not
(10) and connection (13). contacting any other engine components.
e. Apply Tooling (A) to the threads of connection
(10) and connection (13).
f. Install connection (10) and connection (13) to

engine oil rail (1). Tighten the connections to a
UENR4544 9
7. Position clamps (15) onto tube assembly (11) and

tube assembly (8). Install nut and bolts (14) hand
tight. If necessary, repeat Step 7 to install
remaining clamps.
8. Connect tube assembly (5), tube assembly (6),
and tube assembly (7) to engine oil rail (1) and
valve mechanism cover base (2) hand tight.
9. Install bolt (3) to clip (4) hand tighten.
10. Repeat Step 8 through Step 9 to install remaining
tube assembly (5), tube assembly (6), and tube
assembly (7) to engine oil rail (1) and valve
mechanism cover base (2).
Typical example
11. Use a suitable tool to hold connections (21) and

tighten the tube nuts for tube assembly (5), tube
assembly (6), and tube assembly (7). Tighten the
tube nuts to a torque of 15 N·m (133 lb in).
12. Use a suitable tool to hold connection (27) (not
shown) and connection (28). Tighten the tube nuts
for tube assembly (5), tube assembly (6), and tube
assembly (7). Tighten the tube nuts to a torque of
15 N·m (133 lb in).
13. Tighten bolt (3) to a torque of 41 N·m (30 lb ft).
14. Repeat Step 11 through Step 13to tighten
5. Connect tube assembly (11) to connection (13). remaining tube nut for tube assembly (5), tube
Tighten tube nut (12) hand tight. assembly (6), and tube assembly (7).
6. Connect tube assembly (8) to connection (10).

Tighten tube nut (9) hand tight.
10 UENR4544

tighten tube nut (18) for hose assembly (19) to a
19. Tighten bolts (16) for engine oil rail (1) to a torque
of 47 N·m (35 lb ft). Ensure that the tube
assemblies and the hose assembly are not
strained as the bolts are tightened.
tighten tube assembly (11) to a torque of 40 N·m
(30 lb ft). 20. Tighten nuts and bolts (24) for engine oil rail (1) to
a torque of 25 N·m (18 lb ft).
tighten tube assembly (11) to a torque of 100 N·m 21. Turn the battery disconnect switch to the ON
(74 lb ft). position.
17. Tighten nut and bolt (14) to a torque of 25 N·m 22. Switch ON battery charger (if installed) or the
(221 lb in). Repeat Step 17 to tighten the connect the mains supply and connect the
remaining nuts and bolts. negative lead to the batteries.
UENR4544 11
23. Before starting the engine after either engine oil

rail removal and installation or an overhaul of the
engine. Refer to Operation and Maintenance
Manual, Before Starting Engine for the correct
procedure. This procedure should be read in
full before starting of the engine.
i06513475
Governor - Remove
(Electronic Control Unit)
Removal Procedure
NOTICE
component life.
Typical example
2. Mark temporary marks on harness assembly (2),

Accidental engine starting can cause injury or harness assembly (3), and harness assembly (4).
death to personnel working on the equipment. 3. Disconnect Original Equipment Manufacture
To avoid accidental engine starting, disconnect (OEM) harness assembly (2) from governor
the battery cable from the negative (−) battery ter- control unit (1). Refer to the OEM for the correct
minal. Completely tape all metal surfaces of the procedure.
disconnected battery cable end in order to pre-
vent contact with other metal surfaces which 4. Disconnect harness assembly (3) and harness
could activate the engine electrical system. assembly (4) from governor control unit (1).
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.
1. Switch OFF battery charger (if installed) or the

disconnect the mains supply and disconnect the
5. Remove nuts (6) and nuts (11) from bracket (7)
12 UENR4544
6. Remove bracket (7) and governor control unit (1) Note: Note the position of the washer for
from rubber mounts (5). installation purposes.
7. If necessary, follow Step 7 through Step 7.c to
i06513476
remove bracket (10) from the inlet manifold.
a. Remove nuts and bolts (9) and nuts and bolts

Governor - Install
(12) from bracket (10). (Electronic Control Unit)
b. Remove bracket (10) from the inlet manifold.
c. If necessary, remove nuts (8) from rubber

mounts (5). Remove the rubber mounts from
bracket (10). NOTICE
component life.
1. Ensure that all components of the governor control

unit are free from wear or damage. If necessary,
replace any component that is worn or damaged.
8. If necessary, follow Step 8.a through Step 8.c to

remove governor control unit (1) from bracket (7).
a. Remove screws (14) and remove cover (13)

from governor control unit (1).
b. Remove Allen head bolts and nuts (15) from

governor control unit (1).
c. Remove governor control unit (1) from bracket 2. If necessary, follow Step 2.a through Step 2.d to
(8). Remove washers (16) (not shown). install governor control unit (1) to bracket (7).
a. Position governor control unit (1) onto bracket

(8). Position washers (16) (not shown)
between the governor control unit and the
bracket.Ensure that the washers are
correctly positioned between the governor
control unit and the bracket.
b. Install Allen head bolts and nuts (15) to
governor control unit (1). Ensure that the
washers remain between the governor control
unit and the bracket.
UENR4544 13
c. Tighten Allen head bolts and nuts (15) to a

d. Install cover (13) to governor control unit (1).

Install screws (14)and hand tight the screws.
Typical example
6. Connect Original Equipment Manufacture (OEM)

harness assembly (2) to governor control unit (1).
Refer to the OEM for the correct procedure.
Illustration 18 g06030160 7. Connect harness assembly (3) and harness
assembly (4) to governor control unit (1).
install bracket (10) to the inlet manifold. 8. If a replacement electronic governor control unit
has been installed, the feedback for the governor
a. If necessary, install rubber mounts (5) to must be calibrated. Refer to Special Instruction,
bracket (10) and install nuts (8) to the rubber “Pandoras Digital Governor” for the correct
mounts. Tighten the nuts to a torque of 25 N·m procedure.
(18 lb ft). Ensure that the rubber mounts are
not strained as the nuts are tightened.
b. Install bracket (10) to the inlet manifold. Install negative lead to the batteries.
nuts and bolts (9) and nuts and bolts (12) to
the bracket. i06513477
c. Tighten nuts and bolts (9) to a torque of Governor Actuator - Remove

50 N·m (35 lb ft)
4. Install bracket (7) and governor control unit (1) to
and Install
rubber mounts (5).
5. Install nuts (6) and nuts (11) to bracket (7). Tighten
the nuts to a torque of 25 N·m (18 lb ft). Ensure
Removal Procedure
that the rubber mounts are not strained as the nuts NOTICE
are tightened. Keep all parts clean from contaminants.
component life.
14 UENR4544
Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
vent contact with other metal surfaces which
could activate the engine electrical system.
Removal of Governor Actuator

Tube assemblies not shown for clarity
3. Disconnect harness assembly (3) from governor

actuator (4).
4. Remove nuts and bolts (8) from governor actuator
(4).
5. Slide governor actuator (4) rearward and
disconnect spring (6) from lever (5).
6. Remove governor actuator (4) from bracket (9).
7. Remove spring (6) and sleeve (7) (not shown) from
the shaft.
2. Remove bolts (2) from guard (1). Remove the

guard.
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
UENR4544 15
b. If necessary, remove studs (11) from

suspension plate (13).
8. If necessary, remove self-locking nut and bolt (10)

from lever (5). Remove the lever from governor
actuator (4).
Note: Make temporary marks on the lever and the 10. If necessary, follow Step 10.a through Step 10.c
shaft of the governor actuator for installation to remove lever (14) from shaft (15). Do not
purposes. remove the lever unless the lever is damaged,
the oil seal or shaft require replacing.
a. Remove nut and bolt (17) from lever (14).
b. Use a suitable tool to remove pin (16) from

lever (14). Support shaft (15) as the pin is
removed.
c. Remove lever (14) from shaft (15).
NOTICE
component life.
For safe operation and the ability to stop the en-

gine, ensure that the governor actuator will return
Illustration 23 g06016110 the fuel injectors to the “NO FUEL” position.
Tube assemblies not shown for clarity Failure to stop the engine may result in personal
injury or death.
9. If necessary, follow Step 9.a through Step 9.b to
remove bracket (9).
a. Remove nuts (12) from bracket (9). Remove

the bracket from suspension plate (13).
16 UENR4544
Table 2
Required Tools
Loctite 542 Thread and nut

A - 1
lock
Loctite C5-A Anti-Sieze
B - 1
Compound
1. Ensure all components of the governor actuator

and mounting bracket are free from wear or
damage. Replace any component that is worn or
damaged.
2. If lever (15) was removed and the lever is not

going to be replaced with a new assembly. Inspect
oil seal (18) is not leaking or damaged. if the oil
seal is leaking or damaged, follow Step 3.c
through Step 2.g to install a new oil seal.
a. Use as suitable tool to remove oil seal (18)

from housing (19). Ensure that shaft (15) is not
damaged as the oil seal is removed.
b. Ensure that shaft (15) and housing (19) is free

from burrs or damage.
UENR4544 17
Lever.
c. Lubricate a new oil seal (18) with clean engine
oil. Carefully position the oil seal over shaft
(15) and use a suitable tool to install the oil
seal into housing (19). Ensure that the oil seal
is correctly installed into the housing.
d. Install lever (14) onto shaft (15) and install nut

and bolt (17).
e. Align the hole in lever (14) for pin (16) and

position a new pin into the lever. Use a
suitable tool to install the pin into the lever.
Support shaft (15) as the pin is installed.
f. Tighten nut and bolt (17) to a torque of 10 N·m

(89 lb in).
g. Ensure that there is end play between lever

(15) and the housing.
3. If lever (14) was removed due to wear, damage, or
shaft (15) replacement. Follow Step 3.c through
Step 3.g to install new lever (14) assembly to shaft Illustration 27 g06016110
(15).
a. Inspect oil seal (18) is not leaking or damaged. install bracket (9).
if the oil seal is leaking or damaged, follow
Step 3.c through Step 2.g to install a new oil a. If necessary, apply Tooling (A) to the threads
seal. of studs (11). Install the studs to suspension
plate (13) and tighten the studs securely.
b. Ensure that shaft (15) is free from wear or
damage. If the shaft is worn or damaged. b. Position bracket (9) onto suspension plate
Refer to the correct section of Disassembly (13).
and Assembly, Fuel Injection Control Linkage -
Remove and Disassembly and Assembly, Fuel c. Install nuts (12) to bracket (9). Tighten the nuts
Injection Control Linkage - Install for the to a torque of 25 N·m (18 lb ft).
correct procedure.
c. Use as suitable tool to remove oil seal (18)

from housing (19). Ensure that shaft (15) is not
damaged as the oil seal is removed.
d. Ensure that shaft (15) and housing (19) is free

from burrs or damage.
e. Lubricate a new oil seal (18) with clean engine

oil. Carefully position the oil seal over shaft
(15) and use a suitable tool to install the oil
seal into housing (19). Ensure that the oil seal
is correctly installed into the housing.
f. Install a new lever (14) to shaft (15).
g. Loosely install nut and bolt (17) to lever (14).

After the new lever has been installed, install
the remaining components for the governor
actuator before installing pin (16)to lever (14).
Refer to section Adjustment and Set Up
Procedure for a New Governor Actuator
18 UENR4544

equipment.
Tube assemblies not shown for clarity

install lever(5).
a. Position lever (5) on the shaft of governor

actuator (4). Ensure that the lever is aligned
as in Position (X) as shown in Illustration 29 .
b. Install self-locking nut and bolt (10)to lever (5).

Tighten the self-locking nuts and bolts to a
Position (Y) of the spring in levers
Position (Z) of both in levers
UENR4544 19
6. Apply Tooling (B) to the inner part of sleeve (7) (not

shown).
7. Install spring (6) to the shaft and into the lever.
Refer to Illustration 31 for the correct position.
8. Install sleeve (7) (not shown) to the spring and the
shaft.
9. Position governor actuator (4) onto bracket (9).
Install lever (5) to spring (6). Ensure that the levers
are correctly installed, refer to 31 for the correct
position.
10. Slide governor actuator (4) forward. Install bolts
and nuts (8) to the governor actuator. Tighten the
nuts and bolts hand tight. Ensure that the governor Illustration 32 g06030208
actuator has an equal distance across the back
with the bracket.
11. Tighten nuts and bolts (8) to a torque of 10 N·m
(89 lb in).
Note: Ensure that the governor actuator, move

freely without binding.
12. Connect harness assembly (3) to governor

actuator (4).
Adjustment and Set Up Procedure

for a New Governor Actuator Lever
Table 3
Required Tools
21825617 Dial Indicator Group 1

C
- Magnetic Base and Stand 1
1. Follow Step 1.a through Step 1.f to adjust and set

up a new lever (14).
a. Set the governor actuator to the zero position.

Position a 4 mm (0.158 inch) spacer (20)
between the two levers of the lever assembly.
Refer to Illustration 32 for the correct position.
b. Position a 0.3 mm to 0.5 mm

(0.012 inch to 0.020 inch) feeler gauge
between lever (14) and oil seal housing. Refer
to 29 for the correct position.
c. Tighten nut and bolt (17) to a torque of 10 N·m

(89 lb in). Use Tooling (C) to check the end
play of the lever (14). Ensure that the end play
is between 0.3 mm to 0.5 mm
(0.012 inch to 0.020 inch). If the end play is
not between 0.3 mm to 0.5 mm
20 UENR4544
(0.012 inch to 0.020 inch). Loosen the nut and 3. Calibrate the operation of the governor actuator
bolt and repeat Step 1.c to achieve the correct and the governor electronic control unit. Refer to
end play. Operation and Maintenance Manual, “Governor
Actuator - Check” for more information.
d. Remove spacer (20) from between the two
levers of the lever assembly. i06513469
e. After the end play has been set, use a 4 mm Fuel Injection Control Linkage
(0.158 inch) drill to drill through pin (16) hole in
lever (14) and the shaft. - Remove
f. Use a suitable tool to install pin (16)to lever
(14). Support the shaft as the pin is installed.
Removal Procedure
Installation Procedure for Guard Start By:
a. Remove the rocker assemblies. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
b. Remove the cam followers. Refer to
Disassembly and Assembly, “Lifter Group -
Remove” for the correct procedure.
NOTICE
component life.
Removal of the Upper Fuel Injection

Control Linkage and the Setting of the
Governor Actuator
1. Install guard (1) and install bolts (2). Tighten the

bolts to a torque of 25 N·m (18 lb ft).
The ZERO FUEL position on the governor actuator
UENR4544 21
1. Set the governor actuator to the ZERO FUEL

position.
6. If necessary, remove locking nut (9) and spacer

(10). Remove break-back lever (7) from the
cylinder head. Note position of dowel Hole (W) in
2. Remove Allen head bolt (1) for link (2) from fuel
cylinder head for the break-back lever.
injector lever(4). Ensure that the fuel injector lever
is not strained as the Allen head bolt is removed.
Removal of the Stop Control Solenoid
3. Remove spacer (3). and the Stop Lever from the Timing Case
4. Remove nut and bolt (5). Remove link (2).
1. Remove the governor actuator. Refer to
Disassembly and Assembly, “Governor Actuator -
Remove and Install” for the correct procedure.
5. Remove locking nut and bolt (6). Disconnect rod

(8) from break-back lever (7).
22 UENR4544
Illustration 39 g06015102 Illustration 40 g06015156
2. Disconnect harness assembly (14) from solenoid 10. If necessary, follow Step 10.a through Step 10.d
(13). to disassemble bracket (11).
3. Compress the plunger on stop solenoids (13). Use a. Measure the distance of bolt (23) for
suitable cable straps to secure the plunger in the installation purposes.
compressed position
b. Loosen lock nut (24) and remove bolt (23)
4. Remove bolts (12) from solenoid (13). Remove
from bracket (11).
solenoid from bracket (11).
5. Remove pin (18) from shaft (20). Support the shaft c. Measure the distance of bolt (25) for
as the pin is removed installation purposes.
6. Remove circlip (19) from shaft (20) d. Loosen lock nut (26) and remove bolt (25)
from bracket (11).
7. Remove lever (21) from shaft (20). As the shaft is
removed disconnect spring (17) from pin in the
timing case.
8. Remove spring (17) and washers (16) from shaft
(20). Note the orientation of the spring and also
the number of washers for installation purposes.
9. if necessary, remove nuts and bolts (22) from
bracket (11). Remove the bracket and bracket (15)
(not shown) from the timing case.
Note: Make temporary mark on the suspension plate
to show the position of (15) (not shown) for
installation purposes. Note position of thick washer
on bracket (15) (not shown).
UENR4544 23
11. If necessary, follow Step 11.a through Step 11.b

to disassemble lever (21).
a. Remove nut (27) and bolt (31)from lever (21).
b. Remove bush (28), bush (29), and washer

(30) from bolt (31). Note the position of all
components.
Removal of the Fuel Injection Control

Linkage from the Crankcase
1. Remove the Housing Front (Timing Case). Refer to
Disassembly and Assembly, “Housing (Front)
(Timing Case) - Remove” for the correct
procedure.
24 UENR4544
2. Remove locking nut (37) and bolt (36) from rod (8).
If necessary, remove rod (8). Repeat Step 2 to
remove the remaining locking nut, and bolt, and
rods.
3. Remove nuts (32) from plate (34).
4. Remove Allen head bolts (33) from plate (34).
Remove the plate from the cylinder block. Remove
O-ring seal (35) (not shown).
5. Repeat Step 3 through Step 4 to remove remaining
plate (34).
UENR4544 25
9. Push supports (44) for fuel injection control linkage

(42) from the cylinder block and carefully remove
the assembly of the fuel injection control linkage
from the cylinder block.
i06513471
Fuel Injection Control Linkage

- Install
Installation of the Fuel Injection

Illustration 43 g06030187 Control Linkage from the
Crankcase
Table 4
Required Tools

A - 1
Compound
B - LOCTITE 542 1
1. Ensure all components the fuel injection control

linkage are free from wear or damage. Replace
any component that is worn or damaged.
2. Lubricate all the bearing surfaces of the fuel
injection control linkage and rods with clean
engine oil.
6. Remove circlip (39) and washer (38) from rod (40).
7. Remove locking nut and bolt (41) from rod (40)
and remove the rod.
Note: Note the orientating of the rod for installation
purposes.
8. Remove bolts (43) from linkage rod housing (42).
26 UENR4544
3. Carefully install the assembly of fuel injection
control linkage (42) into from the cylinder block.
Push supports (44) for fuel injection control linkage
into the cylinder block. Ensure that the supports
for fuel injection control linkage are correctly
located into the cylinder block.
UENR4544 27
4. Install bolts (43) to linkage rod housing (42). Hand

tighten the bolts.
5. Install a new O-ring seal (35) (not shown) to
supports (44) for fuel injection control linkage.
6. Position plate (34) onto support (44) for fuel
injection control linkage.
7. Install Allen head bolts (33) to plate (34). Install
nuts (32) to the plate. Hand tighten the nuts and
the Allen head bolts.
8. Repeat Step 5 through Step 7 to install remaining
plate (34).
9. Tighten nuts (32) to a torque of 50 N·m (35 lb ft).
Tighten Allen head bolts (33) to a torque of 8 N·m
(70 lb in).
Tighten bolts (43) to a torque of 50 N·m (35 lb ft)
Note: Ensure that the fuel injection control

linkage is free to rotate after the nuts, bolts, and Illustration 48 g06015170
Allen head bolts have been tightened.

3. If necessary, follow Step 3.a through Step 3.d to
10. Install rod (40) to the lever and the fuel injection assemble lever (21).
control linkage. Ensure that the rod is correctly
orientated. a. Apply Tooling (A) to bush (29) Install the bush
into bush (28). Position washer (30) onto bolt
11. Install locking nut and bolt (41) to the rod. Hand (31).
tighten the nut and bolt.
b. Install bolt (31) and washer (30) to bush (29).
12. Install washer (38) onto rod (40) and install circlip
(39). Ensure that the circlip is correctly seated in to c. Install bolt (31) to lever (21). Apply Tooling (B)
the groove. to the threads of the bolt. Install nut (27)to the
13. Tighten locking nuts and bolts (41) to a torque of bolt.
8 N·m (70 lb in). d. Tighten the nut (27) and bolt (31) to a torque of
14. If necessary, install rod (8) into the cylinder block. 47 N·m (35 lb ft). Ensure the bush (28)rotates
freely after the nut and bolt has been
15. Position rod (8) onto fuel injection control linkage tightened.
(42). Install bolt (36) and locking nut bolt (37).
Tighten the locking nut bolt to a torque of 8 N·m
(70 lb in).
16. Repeat Step 14 through Step 15 to install the
remaining rods, bolts, and locking nuts.
17. Install the Housing Front (Timing Case). Refer to
Disassembly and Assembly, “Housing (Front)
(Timing Case) - Remove” for the correct
procedure.
Installation of the Stop Control Solenoid

and the Stop Lever to the Timing Case
1. Ensure all components of the stop control solenoid
and the stop lever are free from wear or damage.
Replace any component that is worn or damaged.
2. Lubricate all the bearing surfaces of the stop lever.
28 UENR4544
4. If necessary, follow Step 4.a through Step 4.b to 5. if necessary, position bracket (11) onto the timing
assemble bracket (11). case and install nuts and bolts (22). Install bracket
(15) (not shown) to the nut and bolt on the rear of
a. Install bolt (23) to bracket (11). Set the bolt to the suspension plate. Align the bracket to the
measurement taken on the removal temporary marks on the suspension plate.
procedure. Tighten lock nut (24)to a torque of
25 N·m (221 lb in). Note: Ensure that the thick washer is correctly
positioned onto the bracket.
b. Install bolt (25) to bracket (11). Set the bolt to
measurement taken on the removal 6. Tighten the nuts and bolts to a torque of 47 N·m
procedure. Tighten lock nut (26)to a torque of (35 lb ft). Ensure that bracket (15) (not shown)
25 N·m (221 lb in). remains correctly orientated.
7. Install spring (17) and washers (16) to shaft (20).
Ensure that the spring is correctly orientated.
8. Install lever (21) to shaft (20). Connect spring (17)
to pin in the timing case and the lever.
9. Install circlip (19) to shaft (20). Ensure that the
circlip is correctly installed into groove of the shaft.
10. Install pin (18) to shaft (20). Support the shaft as
the pin is installed.
11. Position solenoid (13) onto bracket (11). Install
bolts (12). Tighten the bolts to a torque of 47 N·m
(35 lb ft).
12. Remove the cable strap from solenoid (13).
13. Connect harness assembly (14) to solenoid (13).
14. Install the governor actuator. Refer to
Disassembly and Assembly, “Governor Actuator -
UENR4544 29
Installation of the Upper Fuel Injection

Control Linkage and the Setting of the
Governor Actuator
1. Ensure that all components of the upper fuel
injection control linkage are free from wear or
damaged.
5. Position rod (8) onto break-back lever (7). Install

locking nut and bolt (6) to the rod.
6. Tighten locking nut and bolt (6) to a torque of
8 N·m (70 lb in).
2. If necessary, position break-back lever (7) onto the

cylinder head. Ensure that the break-back lever is
located correctly in dowel Hole (W) on the cylinder
head.
3. install spacer (10) and locking nut (9).
4. Insert a 0.25 mm (0.010 inch) feeler gauge
between the arm and the block of break-back lever
(7). Rotate the break-back in a counterclockwise
direction. Tighten the nut to a torque of 50 N·m
(35 lb ft). Remove the feeler gauge.
The ZERO FUEL position on the governor actuator
7. Set the governor actuator to the ZERO FUEL

position.
30 UENR4544
10. Position link (2) onto fuel injector (4) and install
spacer (3).Install Allen head bolt (1) to the link.
11. Tighten locking nut and bolt (5) and Allen head
bolt (1) to a torque of 8 N·m (70 lb in). Ensure that
the fuel injector lever is not strained as the Allen
head bolt is tightened.
12. Calibrate the fuel injector, Refer to Operation and
Maintenance Manual, “Fuel Injector - Inspect/
Adjust” for the correct procedure.
End By:
a. Install the cam followers. Refer to Disassembly
and Assembly, “Lifter Group - Install” for the
correct procedure.
b. Install the rocker assemblies. Refer to
Shaft - Install” for the correct procedure.
i06511856
Fuel Injector - Remove
Removal Procedure
Table 5
Required Tools
A 27610288 Pry Bars 2
Start By:
a. Remove the rocker assembly. Refer to
NOTICE
component life.
8. If a new link (2) is installed, ensure that Dimension NOTICE

(Y) is 85 mm (3.347 inch). The Dimension (Y) is a Care must be taken to ensure that fluids are con-
starting point for the new link, the correct tained during performance of inspection, mainte-
adjustment should be carried out after all links Be prepared to collect the fluid with suitable contain-
have been installed. If three or more links have ers before opening any compartment or disassem-
been installed, all the fuel injectors should be bling any component containing fluids.
calibrated. Refer to “Systems Operation Testing
and Adjusting”Fuel Injector Adjustment for the Dispose of all fluids according to local regulations
and mandates.
correct procedure.
9. Position link (2) onto the break-back Install .locking
nut and bolt (5) to the link.
UENR4544 31
Note: Do not allow the unions to turn when the tube 4. Remove Allen head bolt (8) from clamp (9).
assemblies are disconnected from the fuel rail. Allow
the unions to turn will damage the threads in the fuel NOTICE
rail. Use two spanners to loosen the tube assemblies For engines that have cover extensive service
from the connections. hours, removal of the injectors will require Tool-
ing (A) to be used to free the injector from the car-
bon build-up on the fuel injector nozzle. Failure to
break the carbon build-up on the fuel injector
nozzle could result in the fuel injector sleeve be-
coming dislodged from the cylinder head.
5. Use Tooling (A) to remove clamp (9) and fuel

injector (4) from the cylinder head.
6. Remove clamp (9) from fuel injector (4).
Typical example
2. Disconnect tube assembly (2) and tube assembly

(3) from fuel rail (1). Allow the fuel to drain from the
fuel rail.
7. Remove sealing washer (12) from fuel injector (4).

Remove O-ring seal (10) and O-ring seal (11) from
fuel injector (4).
i06511860
Fuel Injector - Install
Table 6
Required Tools
(continued)
3. Remove Allen head bolt (5) and spacer (7) to
disconnect link (6) from fuel injector (4).
32 UENR4544
(Table 6, contd)
GE50028 Vacuum Pump 1
B Tube
GE50030 7.9 mm (0.31 inch) Outside 1
Diameter
Delphi Lockheed Rubber
C - 1
Grease
NOTICE
component life.
1. Use Tooling (B) to remove any fuel from the
cylinder. 4. Install clamp (9) to fuel injector (4). Install the fuel
injector and the clamp to the cylinder head as an
Note: Evacuate as much fuel as possible from the assembly.
cylinder before installing the fuel injector.
5. Install Allen head bolt (8) to clamp (9) finger tight.
Rotate injector (4) in a clockwise direction against
the clamp. Ensure that the fuel injector is pushed
firmly downward against the seat in the cylinder
head. Tighten the Allen head bolt to a torque of
95 N·m (70 lb ft).
(X) NO FUEL position
2. Install a new O-ring seal (10) and a new O-ring
seal (11) to fuel injector (4). Lubricate the O-ring 6. Rotate the arm on fuel injector (4)
seals with Tooling (C). Install a new sealing counterclockwise to Position (X). The fuel injector
washer (12) to fuel injector (4). is now in the NO FUEL position.
3. Ensure that the sleeve for the fuel injector in the

cylinder head is clean and free from damage. If
necessary, replace the sleeve for the fuel injector.
Refer to Disassembly and Assembly, “Fuel Injector
Sleeve - Remove” and Disassembly and
Assembly, “Fuel Injector Sleeve - Install” for the
correct procedures.
UENR4544 33
Note: Do not allow the unions to turn when the tube

assemblies are connected to the fuel rail. Allowing
the unions to turn when the tube assemblies are
connected will damage the threads in the fuel rail.
Use two spanners to tighten the tube assemblies to
the connections.
10. Connect tube assembly (3) to fuel rail (1). Tighten

tube nuts for tube assembly (3) to a torque of
20 N·m (177 lb in).
Note: Do not allow the unions to turn when the tube

assemblies are connected to the fuel rail. Allowing
the unions to turn when the tube assemblies are
connected will damage the threads in the fuel rail.
Illustration 62 g01440095 Use two spanners to tighten the tube assemblies to
the connections.
7. Position spacer (7) and link (6) on fuel injector (4).
11. Turn the fuel supply to the ON position.
Install Allen head bolt (5). Tighten the Allen head
bolt to a torque of 8 N·m (70 lb in). 12. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
8. Calibrate the fuel injectors, Refer to Operation and
- Prime” for the correct procedure.
Maintenance Manual, “Fuel Injector - Inspect/
Adjust” for the correct procedure. End By:
Note: If three or more fuel injectors have been a. Install the rocker assembly. Refer to
installed, all the fuel injectors should be calibrated. Disassembly and Assembly, “Rocker Arm and
i06513472
Fuel Injector Sleeve - Remove
Removal Procedure
Table 7
Required Tools
Drill (22 mm with 60 Degree

A - 1
Point)
Tap (M36 or 1 3/8 inch -

B - 1
UNF)
Start By:
a. Remove the cylinder head. Refer to
Illustration 63 g01439660 Disassembly and Assembly, “Cylinder Head -
Typical example Remove” for the correct procedure.
9. Connect tube assembly (2) to fuel rail (1). Tighten NOTICE

the tube nut for the tube assembly to a torque of Keep all parts clean from contaminants.
100 N·m (74 lb ft). Contaminants may cause rapid wear and shortened
component life.
34 UENR4544
1. Place the cylinder head in the inverted position on 4. Remove O-ring seal (2) from the cylinder head.
a suitable support. Use Tooling (A) to drill out the
swaging from sleeve (1). i06513473
Note: Take care to avoid drilling into the cylinder Fuel Injector Sleeve - Install
head.
2. Place the cylinder head in the upright position.

Screw Tooling (B) into sleeve (1).
Table 8
Required Tools

C - 1
Grease
D T85002/2 Injector Bush Insertion Tool 1
Injector Bush Expanding Tool

E T85002/6 1
(Lower)
Injector Bush Expanding Tool

F T85002/58 1
(Upper)
G T85002/156 Injector Bush Swaging Tool 1
H T85002/7 Injector Bush Facing Cutter 1
J T85002/14B Injector Bush Depth Gauge 1
NOTICE
Removing the sleeve from the cylinder head Contaminants may cause rapid wear and shortened
component life.
3. Place the cylinder head in the inverted position.
Insert a suitable brass rod into the injector bore of 1. Ensure that the bore in the cylinder head for the
the cylinder head. Use a hammer and the brass sleeve is clean and free from corrosion.
rod to remove Tooling (B) and sleeve (1) from the
cylinder head.
UENR4544 35
2. Lubricate a new O-ring seal (2) with Tooling (C).

Install the new O-ring seal to the bore in the
cylinder head.
3. Place a new sleeve (1) over Tooling (D) and install

the locating pin.
4. Place the cylinder head in the upright position on a

suitable support. Position sleeve (1) and Tooling
(D) in the bore in the cylinder head. Carefully tap
the sleeve into position until Distance (Y) is
1.5 mm (0.060 inch). Remove Tooling (D).
Note: Ensure that the O-ring seal is not damaged or
displaced during this procedure.
36 UENR4544
5. Use Tooling (G) to swage the end of sleeve (1) 7. Place the cylinder head in the upright position. Use
sufficiently so that the sleeve is held in position. Tooling (F) to expand top of sleeve (1).
Note: The final forming of the swage is completed
after the sleeve has been expanded.
8. Use Tooling (G) to swage the end of sleeve (1).

Illustration 72 g06013947 Tighten the nut on Tooling (G) to a torque of
55 N·m (40 lb ft) to swage the end of the sleeve to
6. Place the cylinder head in the inverted position. the correct form.
Use Tooling (E) to expand the bottom of sleeve
(1).
UENR4544 37
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i06511714
Air Cleaner - Remove and

Install
Removal Procedure
NOTICE
component life.
Illustration 76 g06013954 1. Loosen hose clamp (1) and hose clamp (3) for
hose assembly (2).
9. Use Tooling (J) to check Distance (Z). Use Tooling
(H) to face sleeve (1) so that Distance (Z) is 2. Attach a suitable lifting equipment to air cleaner
122.6 ± 0.166 mm (4.8207 ± 0.004 inch). assembly (8). The weight of the air cleaner is
approximately 15 kg (33 lb).
10. Ensure that sleeve (1) is free from burrs or
damage after the installation procedure has been 3. Remove bolts (4) and remove air cleaner
completed. Failure to ensure that the injector assembly (8) from bracket (5).
sleeve is free from burrs or damage could damage 4. Remove hose assembly (2), hose clamp (1), and
to the injector O-ring seals. hose clamp (3) from turbocharger (6).
5. If necessary, remove air cleaner indicator (7) from
air cleaner assembly (8).
38 UENR4544
6. If necessary , follow 1 Step through Step 5 to b. Attach a suitable lifting device to air cleaner
remove the remaining air cleaner assembly. bracket (5). The weight of the air cleaner
bracket is approximately 8 kg (17 lb).
c. Remove nuts and bolts (5) from air cleaner

bracket (5).
d. Use the suitable lifting device to remove air

cleaner bracket (5) from the inlet manifold.
e. Remove plate (15) and O-ring seal (16) from

inlet manifold (17).
f. If necessary, make temporary marks on

bracket (9) and bracket (11) for installation
purposes. Remove nuts and bolts (10) and
remove the brackets from bracket (5).
Table 9
Required Tools
Illustration 78 g06018882 International Products P-80

A - Emulsion Rubber Assembly 1
Lubricant
NOTICE
component life.
1. Ensure all components for air cleaner and brackets

are free from wear or damage. If necessary,
replace any component that is worn or damaged.
7. If necessary, Follow Step 7.a through Step 7.d to

remove air cleaner bracket (5) from inlet manifold
(17).
a. Disconnect the harness assembly from boost

pressure sensor (12) and remove the boost
pressure sensor. Refer to Disassembly and
Assembly, Boost Pressure Sensor - Remove
and Install for the correct procedure.
UENR4544 39
d. Position plate (16) between air cleaner bracket

(6) and inlet manifold (17). Ensure that the O-
ring seal is not dislodged from the recess of
the inlet manifold.
e. Install nuts and bolts (5) to air cleaner bracket
(6). Tighten the nuts and bolts to a torque of
41 N·m (30 lb ft).
f. Position bracket (9) and bracket (11) onto

bracket (5). Install nuts and bolts (10) hand
tight.
2. If necessary, Follow Step through Step to install air

cleaner bracket (5) to inlet manifold (17).
a. Install a new O-ring seal (16) into the recess of

inlet manifold (17). Ensure that the O-ring seal Illustration 83 g06018927
is correctly installed into the recess.
3. Apply Tooling (A) to both the inner section of hose
b. Attach a suitable lifting device to install air assembly (2).
cleaner bracket (5). The weight of the air
cleaner bracket is approximately 8 kg (17 lb). 4. Install hose clamp (1) and hose clamp (3) to hose
assembly (2). Ensure that the hose clamps are
c. Use the suitable lifting device to position air correctly orientated.
cleaner bracket (5) onto inlet manifold (17).
40 UENR4544
5. Install hose assembly (2) to turbocharge (6).

Ensure that the hose assembly is correctly
orientated.
6. If necessary, install air cleaner indicator (7) to air
cleaner assembly (8).
7. Attach a suitable lifting equipment to air cleaner
assembly (8). The weight of the air cleaner is
8. Use a suitable lifting device to position air cleaner
(8) onto hose assembly (2). Align the air cleaner
assembly with the hose and bracket (5).
9. Install bolts (4) to air cleaner assembly (8). Tighten
the bolts to a torque of 50 N·m (37 lb ft).
10. Tighten hose clamp (1) and hose clamp (3) to a
11. If necessary , tighten nuts and bolts (10) for
bracket (9) and bracket (10) to a torque of 50 N·m
(37 lb ft).
12. If necessary , follow Step 3 through Step 11 to
install the remaining air cleaner assembly.
13. If necessary, replace the air filter elements to the
air cleaner assemblies. Refer to Operation and
Maintenance Manual, Engine Air Cleaner Element Illustration 84 g06007463
-Replace for the correct procedure.
1. Remove the Original Equipment Manufacture
i06511742 (OEM) exhaust system (1) from exhaust elbow (7).
2. If equipped with an exhaust temperature sensor.
Turbocharger - Remove Remove exhaust temperature sensor (6) from
exhaust elbow (7). Refer to OEM for the correct
Removal Procedure procedure.
3. Remove exhaust elbow (7). Refer to Disassembly
and Assembly, Exhaust Elbow - Remove and
NOTICE Install for the correct procedure.
4. To remove the inner turbocharger, remove air
Contaminants may cause rapid wear and shortened cleaner (3) and hose assembly (2). Refer to
component life. Disassembly and Assembly, Air Cleaner - Remove
and Install for the correct procedure.
NOTICE 5. To remove the outer turbocharger, remove air
Care must be taken to ensure that fluids are con- cleaner (4) and hose assembly (5). Refer to
nance, testing, adjusting and repair of the product. Disassembly and Assembly, Air Cleaner - Remove
Be prepared to collect the fluid with suitable contain- and Install for the correct procedure.
ers before opening any compartment or disassem-
Dispose of all fluids according to local regulations
and mandates.
UENR4544 41
Removal Procedure For Outer 4. Sufficiently loosen V-band clamp (15) and position
Turbocharger the V-band clamp away from the outlet of
turbocharger (14).
5. Attach a suitable lifting equipment to support the
turbocharger (14). The weight of the turbocharger
is approximately 35 kg (77 lb).
6. Remove nuts and bolts (17) and remove
turbocharger (14) from the exhaust manifold
assembly.
7. Remove gasket (18) (not shown) and O-ring seal
(16) (not shown).
8. Plug all open ports turbocharger (14) to prevent
the entry of dirt. Plug open port tube assembly (19)
and tube assembly (20).
9. If necessary. remove connection (20a) from the
rear tube assembly. Refer to the section removal
procedure for inner and outer turbocharger
connections Disassembly and Assembly,
Turbocharger - Remove for the correct procedure.
Outer turbocharger
1. Loosen nut and bolt (11) for clamp (12). Remove

the clamp from tube assembly (19) and tube
assembly (20).
2. Remove Allan head bolts (9) for tube assembly
(20) and position the tube assembly away from
turbocharger (14). Remove gasket (8) (not
shown).
3. Remove Allan head bolts (13) (not shown) for tube
assembly (19) and position the tube assembly
away from turbocharger (14). Remove gasket (10)
(not shown).
42 UENR4544
Removal Procedure For Inner 4. Sufficiently loosen V-band clamp (28) and position
Turbocharger the V-band clamp away from the outlet of
turbocharger (27).
5. Attach a suitable lifting equipment to support the
turbocharger (27). The weight of the turbocharger
is approximately 35 kg (77 lb).
6. Remove nuts and bolts (30) and remove
turbocharger (27) from the exhaust manifold
assembly.
7. Remove gasket (31) (not shown) and O-ring seal
(29) (not shown).
8. Plug all open ports of turbocharger (14) to prevent
the entry of dirt. Plug open port of tube assembly
(19) and tube assembly (20).
9. If necessary. remove connection (33a) from the
rear tube assembly. Refer to the section removal
Removal Procedure For Inner and

Outer Turbocharger Connections
Outer turbocharger not shown for clarity
1. Loosen nut and bolt (24) for clamp (25). Remove

the clamp from tube assembly (32) and tube Illustration 87 g06020258
assembly (33).
2. Remove Allan head bolts (22) for tube assembly 1. If necessary, follow Step 1.a through Step 1.b to
(33) and position the tube assembly away from remove elbow connection (34) and connection
turbocharger (27). Remove gasket (21) (not (35) from rear tube assembly (38).
shown).
a. Make temporary marks on elbow connection
3. Remove Allan head bolts (26) (not shown) for tube (34) and rear tube assembly (38). Remove
assembly (32) and position the tube assembly elbow connection from the rear tube
away from turbocharger (27). Remove gasket (23) assembly. Remove seal (37).
(not shown).
UENR4544 43
b. Make temporary marks on connection (35)

and rear tube assembly (38). Remove
connection from the rear tube assembly.
Remove seal (36).
Removal Procedure for

Turbochargers Oil feed and Drain
Tube Assemblies
1. Removal of the oil feed and the drain tube
assemblies can be carried out without removal of
the turbo charge assemblies. To remove the oil
feed and the drain tube assemblies from the
turbocharger, the tube assemblies need
disconnecting from the turbochargers. Refer to the
correct section of Disassembly and Assembly,
44 UENR4544
2. Disconnect hose assembly (20) from oil feed
manifold (41). Remove O-ring seal (39) (not 8. Disconnect hose assembly (32) from oil drain
shown) from the oil feed manifold. manifold (51). Remove O-ring seal (56) from
connection (55).
3. Disconnect hose assembly (33) from oil feed
manifold (41). Remove O-ring seal (40) (not 9. Disconnect hose assembly (19) from oil drain
shown) from the oil feed manifold. manifold (51). Remove O-ring seal (59) from
connection (58).
4. Remove hose assembly (46) from oil feed manifold
(41) and connection (48). Remove O-ring seal (44) 10. If necessary, follow Step 10.a through Step 10.d
(not shown) and O-ring seal (49) (not shown). to remove oil drain manifold (51) from the cylinder
block and remove connection (55) and connection
5. Remove bolts (42) and remove oil feed manifold (58) from the oil drain manifold.
(41) from bracket (45).
6. If necessary, remove bolts (43) (not shown) and a. Remove nuts (53) and remove oil drain
bolts (47) from bracket (45). Support the bracket manifold (51) from the cylinder block. Remove
as the bolts are removed. O-ring seal (52) (not shown).
7. If necessary. remove connection (48) from the b. Position oil drain manifold (51) in suitable
cylinder block. Remove sealing washer (50). support.
c. Remove connection (55) and connection (58)

from oil drain manifold (51).
UENR4544 45
d. Remove O-ring seal (54) and O-ring seal (57).
i06511743
Turbocharger - Install
Installation Procedure for

Turbochargers Oil feed and Drain
Tube Assemblies
1. Installation of the oil feed and the drain tube
assemblies can be carried out without removal of
the turbo charge assemblies. To installation the oil
feed and the drain tube assemblies to the
turbocharger, the tube assemblies need
connecting to the turbochargers. Refer to the
Turbocharger - Install for the correct procedure.
2. Ensure all tube assemblies and all components
are free from damage, wear, or restriction.
Replace any component that is worn, damaged, or
restricted.
3. Ensure that all the gasket surfaces are free from
damage and free from damage. Illustration 91 g06028754

install connection (55) and connection (58) to oil
drain manifold (51) and Install to the oil drain
manifold to the cylinder block
a. Position oil drain manifold (51) in suitable

support.
b. Install a new O-ring seal (54) and a new O-ring

seal (57) to connection (55) and connection
(58).
c. Install connection (55) and connection (58) to

oil drain manifold (51). Tighten the
connections to a torquer of 260 N·m (192 lb ft)
.
d. Install a new O-ring seal (52) (not shown) to oil
drain manifold (51). Position the oil drain
manifold onto the cylinder block and install
nuts (53). Tighten the nuts to a torque of
47 N·m (35 lb ft).
2. Install a new O-ring seal (56) and a new O-ring
seal (59) to connection (55) and connection (58).
Ensure that the O-ring seals are correctly installed
into the recesses of the connections.
46 UENR4544
3. Connect hose assembly (32) and hose assembly

(19) to oil drain manifold (51). Ensure that the
hose assemblies are connected to correct
connections on the oil drain manifold. If the
turbochargers are installed, connected hose
assembly (32) and hose assembly (19) to the
turbochargers. Refer to the correct section of
Disassembly and Assembly, Turbocharger - Install
for the correct procedure.
If the turbochargers are not installed. Refer to the
Turbocharger - Install for the correct installation
procedure for the hose assemblies.
4. Use a heavy duty, 41 mm (1.615 inch) crows foot
to tighten hose assembly (32) and hose assembly
(19) to a torque of 220 N·m (162 lb ft).
UENR4544 47
of the oil feed manifold.

f. Connect hose assembly (46) to oil feed
manifold (41). Tighten the hose assembly to a
torque of 110 N·m (80lb ft)
7. Install a new O-ring seal (39) (not shown) and a
new O-ring seal (39) (not shown) to oil feed
manifold (41). Ensure that the O-ring seals are
correctly installed into the recesses of the oil feed
manifold.
8. Connect hose assembly (20) and hose assembly
(20) to oil feed manifold (41). Ensure that the hose
assemblies are connected to correct connections
on the oil feed manifold. If the turbochargers are
installed, connected hose assembly (32) and hose
assembly (19) to the turbochargers. Refer to the
If the turbochargers are not installed. Refer to the
Turbocharger - Install for the correct installation
procedure for the hose assemblies.
Installation Procedure For Inner

Illustration 93 g06028418 and Outer Turbocharger
Connections
5. If necessary. follow Step 5.a through Step 5.b to
Table 10
install connection (48) to the cylinder block.
Required Tools
a. Install a new sealing washer (50) to
connection (48).
International Products P-80
b. Install connection (48) to the cylinder block. A - Emulsion Rubber Assembly 1
Tighten the connection to a torque of 110 N·m Lubricant
(81 lb ft). Delphi Lockheed Rubber
B - 1
Grease
6. If necessary. follow Step 6.a through Step 6.f to
install bracket (45), oil feed manifold (41) and hose Loctite C5-A Anti-Sieze
C - 1
Compound
assembly (46).
a. Position bracket (45) onto flywheel housing

and the exhaust manifold. Install bolts (43)
(not shown) and bolts (47) to the bracket.
Support the bracket as the bolts are installed.
b. Tighten bolts (43) (not shown) and bolts (47)

to a torque of 47 N·m (35 lb ft).
c. Loosely install hose assembly (46) to

connection (48).
d. Position oil feed manifold (41) onto bracket

(45). Install bolts (42) and tighten the bolts to a
e. Install a new O-ring seal (44) (not shown) to oil

feed manifold (41). Ensure that the O-ring
seals are correctly installed into the recesses
48 UENR4544
1. Ensure that the turbocharger is clean and free from

damage. Inspect the turbocharger for wear. Refer
to Systems Operation, Testing and Adjusting,
“Turbocharger” for more information.
2. Ensure that all tube assemblies are clean and free
from restrictions.
Turbocharger Orientation

install elbow connection (34) and connection (35)
to rear tube assembly (38).
a. Apply Tooling (A) to the inner and out section

of seal (37). Install the seal to elbow
connection (34). Ensure that the seal is not
damaged and is installed squarely positioned
onto elbow connection.
b. Align temporary marks on elbow connection
(34) and rear tube assembly (38). Install the
elbow connection to the rear tube assembly.
Ensure that the seal is not damaged and the
temporary marks remain correctly aligned.
c. Apply Tooling (A) to the inner and out section 1. If necessary, follow Step 1.a through Step 1.b to
of seal (36). Install the seal to connection (35). orientate the rotate on the body turbocharger.
Ensure that the seal is not damaged and is
a. Loosen V-band clamp (34) and V-band clamp
installed squarely positioned onto elbow
(35). Ensure that the housings are free to
connection.
rotate on the body of turbocharger (36).
d. Align temporary marks on connection (35) and
Note: Do not allow the housings to come in
rear tube assembly (38). Install the connection
contact with the turbine or the compressor
to rear tube assembly. Ensure that the seal is wheels.
not damaged and the temporary marks remain
correctly aligned. b. If necessary, remove the V-band clamps and
clean the mating surfaces of the turbocharger.
Installation Procedure Lubricate the mating surfaces with Tooling (C)
and install the V-band clamps.
NOTICE
Note: Do not allow the housings to come in
Contaminants may cause rapid wear and shortened contact with the turbine or the compressor
component life. wheels.
UENR4544 49
Installation Procedure For Inner 4. Position turbocharger (27) onto the exhaust
Turbocharger manifold assembly. Install a new gasket (31) (not
shown) between the turbocharger and the exhaust
manifold assembly.
5. Apply Tooling (C) to nuts and bolts (30). Install the
nuts and bolts to turbocharger (27) and exhaust
manifold assembly. Tighten the nuts and bolts
hand tight.
Note: Care should be taken not to dislodge the O-

ring seal from the inlet connection.
6. Position V-band clamp (28) onto the outlet of

turbocharger (27) and the inlet connection. Tighten
the V-band clamp hand tight.
7. Remove plugs from turbocharger (27), tube
assembly (32) and tube assembly (33).
8. Position a new gasket (23) (not shown) between
turbocharger (27) and tube assembly (32). Install
Allan head bolts (26) (not shown). Hand tight the
Allan head bolts.
Allan head bolts (22). Hand tight the Allan head
bolts.
10. Position clamp (25) onto tube assembly (32) and
tube assembly (33). Tighten nut and bolt (24) for
the clamp hand tight.
(43 lb ft).
12. Tighten Allen head bolts (26) to a torque of
47 N·m (35 lb ft).
47 N·m (35 lb ft).
14. Tighten nut and bolt (24) for clamp (25) to a
15. Tighten V-band clamp (28) to a torque of 9 N·m
(80 lb in). Ensure that the V-band clamp is
Outer turbocharger not shown for clarity
correctly seated onto turbocharger (27) and the
inlet connection.
1. If necessary. install connection (33a) to the rear
tube assembly. Refer to the section installation
2. Apply Tooling (B) to a new O-ring seal (29) (not
shown). Install the O-ring seal into the recess of
the inlet connection.
3. Attach a suitable lifting equipment to turbocharger
(27). The weight of the turbocharger is
50 UENR4544
Note: Ensure that the turbocharger compressor

and the turbine wheels are free to rotate.
b. Lightly tap the V-band clamps with a soft faced

hammer to seat the V-band clamps. Again,
tighten the V-band clamps to a torque of 9 N·m
(80 lb in). Repeat this Step 16.c until the V-
band clamps are correctly seated onto the
turbocharger.
c. After V-band clamp (34) and V-band clamp

(35) have been correctly seated, ensure that
the turbocharger compressor and the turbine
wheels are free to rotate. If the turbocharger
compressor and the turbine wheels are not
free to rotate, slacken the V-band clamps and
repeat Step 16.a and Step 16.b.
16. If necessary, follow Step 16.a through Step 16.c

to tighten V-band clamp (34) and V-band clamp
(35).
a. Tighten V-band clamp (34) and V-band clamp

(35) on the turbocharger to a torque of 9 N·m
(80 lb in).
UENR4544 51
Installation Procedure For Outer 4. Position turbocharger (14) onto the exhaust
Turbocharger manifold assembly. Install a new gasket (18) (not
shown) between the turbocharger and the exhaust
manifold assembly.
5. Apply Tooling (C) to nuts and bolts (17). Install the
nuts and bolts to turbocharger (14) and exhaust
manifold assembly. Tighten the nuts and bolts
hand tight.
Note: Care should be taken not to dislodge the O-

ring seal from the inlet connection.
6. Position V-band clamp (15) onto the outlet of

turbocharger (14) and the inlet connection. Tighten
the V-band clamp hand tight.
7. Remove plugs from turbocharger (14), tube
assembly (19) and tube assembly (20).
Allan head bolts (13) (not shown). Hand tighten
the Allan head bolts.
Allan head bolts (9). Hand tighten the Allan head
bolts.
10. Position clamp (12) onto tube assembly (19) and
tube assembly (20). Tighten nut and bolt (11) for
the clamp hand tight.
(43 lb ft).
47 N·m (35 lb ft).
13. Tighten Allen head bolts (9) to a torque of 47 N·m
(35 lb ft).
14. Tighten nut and bolt (11) for clamp (12) to a
(80 lb in). Ensure that the V-band clamp is
Outer turbocharger
correctly seated onto turbocharger (14) and the
inlet connection.
1. If necessary. install connection (20a) to the rear
tube assembly. Refer to the section installation
2. Apply Tooling (B) to a new O-ring seal (16) (not
shown). Install the O-ring seal into the recess of
the inlet connection.
3. Attach a suitable lifting equipment to turbocharger
(14). The weight of the turbocharger is
52 UENR4544
b. Ensure that the turbocharger compressor

and the turbine wheels are free to rotate.
c. Lightly tap the V-band clamps with a soft faced
(80 lb in). Repeat this Step 16.c until the V-
band clamps are correctly seated onto the
turbocharger.
d. After V-band clamp (34) and V-band clamp

(35) have been correctly seated, ensure that
the turbocharger compressor and the turbine
wheels are free to rotate. If the turbocharger
compressor and the turbine wheels are not
free to rotate, slacken the V-band clamps and
repeat Step 16.aand Step 16.d.
17. After the installation of inner turbocharger, install

air cleaner (3) and hose assembly (2). Refer to
Disassembly and Assembly, Air Cleaner - Remove
Illustration 101 g06007979 and Install for the correct procedure.
18. After the installation of outer turbocharger, install
16. If necessary, follow Step16.a through Step 16.c to
air cleaner (4) and hose assembly (5). Refer to
tighten V-band clamp (34) and V-band clamp (35).
Disassembly and Assembly, Air Cleaner - Remove
a. Tighten V-band clamp (34) and V-band clamp and Install for the correct procedure.
(35) on the turbocharger to a torque of 9 N·m 19. Install exhaust elbow (7). Refer to Disassembly
(80 lb in). and Assembly, Exhaust Elbow - Remove and
Install for the correct procedure.
UENR4544 53
20. If the engine is equipped with exhaust

temperature sensor. Install exhaust temperature
sensor (6) from exhaust elbow (7). Refer to OEM
21. Install the Original Equipment Manufacture
(OEM) exhaust system (1) to exhaust elbow (7).
i06548424
Air Lines - Remove and Install

(Turbocharger Compressor
Outlet Tube Assemblies)
Removal Procedure for Front

Section of Tube Assembly
NOTICE
component life.
1. The turbocharger compressor outlet tube

assemblies can be removed as an assembly or
the turbocharger compressor outlet tube
assemblies can be removed individually. For
removal of individually section all or part of this
removal procedure can be used.
2. Remove heat shield (1) from the hose assembly.
54 UENR4544
3. Loosen hose clamps (3) for hose assembly (4).

4. Remove nuts and bolts (6) and nuts and bolts (7).
Note the position of different length bolts.
5. Slide hose assembles (4) forward along tube
assembly (2). Remove gasket (5) (not shown).
6. Loosen hose clamps (11) for hose assembly (12)
7. Remove nuts (9) from clamp (10). Remove the
clamp from tube assembly (8).
8. Remove tube assembly (8) from hose assembly
(12).

remove bracket (14), bracket (15), and bracket
(17).
a. Make temporary marks on bracket (14) and

the back plate for installation purposes.
Remove nuts and bolts (13) from the bracket
UENR4544 55
support the bracket as the nuts and bolts are

removed. Remove the bracket from the back
plate.
b. Make temporary marks on bracket (15) and

bracket (17).
c. Remove nuts and bolts (16) and remove

bracket (15) from bracket (17).
d. Make temporary marks on cam follower

housing and bracket (17). Remove bolts (18)
from the bracket and remove the bracket.
Removal Procedure for Center

NOTICE
component life.
1. Make temporary marks on hose assembly (12) and 3. Remove bolts (23) from tube assembly (22).
tube assembly (22). Loosen hose clamps (19) for
4. Remove bolts (24) and remove tube assembly
the hose assembly. Remove the hose assembly
(22). Remove gasket (25) (not shown).
from tube assembly (22).
2. Remove nuts (20) from clamp (21). Remove the
clamp from tube assembly (22).
56 UENR4544

remove bracket (26), bracket (28), and bracket
(30).
a. Make temporary marks on bracket (26) and Illustration 108 g06019781

bracket (28) for installation purposes. Remove
nuts and bolts (27) and remove the bracket. 1. Loosen V-band clamp (32) and V-band clamp (33).
Sufficiently loosen the V-band clamps to allow
b. Make temporary marks on bracket (28) and
removal of rear tube assembly (37).
the cam follower housing. Remove bolts (29)
and remove the bracket. 2. Remove bolts (36) from rear tube assembly (37).
c. Make temporary marks on cam follower 3. Loosen bolts (35) for bracket (34). Sufficiently
housing and bracket (30). Remove bolts (31) loosen the bolts to allow removal of rear tube
and remove the bracket. assembly (37).
4. Remove rear tube assembly (37).Care should be
Removal Procedure for Rear taken not to damage the O-ring seal sealing
Section of Tube Assembly faces of the turbocharger or the tube
assemblies.
NOTICE
Keep all parts clean from contaminants. 5. If necessary, remove bolts (35) and remove
bracket (34).
component life.
UENR4544 57
NOTICE
component life.
The turbocharger compressor outlet tube assemblies
can be installed as an assembly or the turbocharger
compressor outlet tube assemblies can be installed
individually. For installed of individually section all or
part of this installed procedure can be used.
1. Ensure all components of the turbocharger
compressor outlet tube assemblies, are free from
wear or damage. If necessary, replace any
component that is worn or damaged.
6. If necessary, follow Step 6.a through Step 6.f to

disassemble rear tube assembly (37).
a. Remove O-ring seal (38) from connection

(41).
b. Remove O-ring seal (39) from connection

(40).
c. Remove V-band clamp (32) from connection

(41).
d. Remove V-band clamp (33) from connection

(40).
e. Make temporary marks on connection (40)
and rear tube assembly (37). Remove 2. If necessary, follow Step 2.a through Step 2.h to
connection from the rear tube assembly. assemble rear tube assembly (37).
Remove seal (42).
a. Apply Tooling (A) to the inner and out section
f. Make temporary marks on elbow connection of seal (43). Install the seal to elbow
(41) and rear tube assembly (37). Remove connection (41). Ensure that the seal is not
elbow connection from the rear tube damaged and is installed squarely positioned
assembly. Remove seal (43). onto elbow connection.
Installation Procedure for Rear b. Align temporary marks on elbow connection

(41) and rear tube assembly (37). Install the
Section of Tube Assembly elbow connection to rear tube assembly (37).
Table 11 Ensure that the seal is not damaged and the
Required Tools temporary marks remain correctly aligned.
Tool Part Number Part Description Qty c. Install a new O-ring seal (38) to elbow
International Products P-80 connection (41). Ensure that the O-ring seal is
A - Emulsion Rubber Assembly 1 correctly positioned into the recess of the
Lubricant elbow connection.
58 UENR4544
d. Install V-band clamp (32) to elbow connection

(41). Ensure that the V-band clamp is correctly
oriented.
e. Apply Tooling (A) to the inner and out section
of seal (42). Install the seal to connection (40).
Ensure that the seal is not damaged and is
installed squarely positioned onto elbow
connection.
f. Align temporary marks on connection (40) and
rear tube assembly (37). Install the connection
to rear tube assembly. Ensure that the seal is
not damaged and the temporary marks remain
correctly aligned.
g. Install a new O-ring seal (39) to connection

(40). Ensure that the O-ring seal is correctly
positioned into the recess of the connection.
h. Install V-band clamp (33) to connection (40).

Ensure that the V-band clamp is correctly Illustration 111 g06019781
oriented.
3. If necessary, position bracket (34) onto the cylinder

block. Install bolts (35) hand tight. Ensure that clip
for the wiring harness is located onto the correct
bolt.
4. Install rear tube assembly (37) onto bracket (34).
Install bolts (36).Care should be taken not to
damage the O-ring seal faces of the
turbocharger or the tube assemblies.
5. Tighten bolts (35) for bracket (34) hand tight.
UENR4544 59
6. Install V-band clamp (32) and V-band clamp (33) to

connections and the turbochargers. Tighten the V-
band clamp hand tight.Ensure that the
connection is correctly aligned and are
correctly seated onto the turbochargers.
7. Tighten bolts (35) to a torque of 50 N·m (35 lb ft).
9. Tighten V-band clamp (32) and V-band clamp (33)
on the turbocharger to a torque of 9 N·m (80 lb in)
.
Lightly tap the V-band clamps with a soft faced
hammer to seat the V-band clamps. Again, tighten
the V-band clamps to a torque of 9 N·m (80 lb in). Illustration 113 g06019766
Repeat this Step 9 until the V-band clamps are
secure. Seating the V-band clamps on the 3. If necessary, follow Step through Step to install
turbocharger refer to Illustration 112 .
bracket (26), bracket (28), and bracket (30).
Installation Procedure for Center a. Align temporary marks and install bracket (30)
Section of Tube Assembly onto cam follower housing. Install bolts (31)
Table 12 hand tight.
Required Tools b. Align temporary marks and install bracket (28)
Tool Part Number Part Description Qty onto cam follower housing. Install bolts (29)
hand tight.
International Products P-80
A - Emulsion Rubber Assembly 1 c. Align temporary marks and install bracket
Lubricant
(26). Install nuts and bolts (27) hand tight.
NOTICE
component life.

assemblies can be installed as an assembly or the
turbocharger compressor outlet tube assemblies
can be installed individually. For installed of
individually section all or part of this installed
procedure can be used.
60 UENR4544
8. Tighten bolts (24) and bolts (23) to a torque of

50 N·m (35 lb ft).
50 N·m (35 lb ft).
Tighten nuts and bolts (27) to a torque of 50 N·m
(35 lb ft).
Installation Procedure for Front

Table 13
Required Tools
4. Position tube assembly (22) onto the brackets. International Products P-80
Install a new gasket (25) (not shown) between the A - Emulsion Rubber Assembly 1
tube assemblies. Install bolts (24) hand tight. Lubricant
5. Install clamp (21) to tube assembly (22). Install

nuts (20) hand tight. NOTICE
6. Apply Tooling (A) to inner section of hose
assembly (12). Install the hose assembly to tube Contaminants may cause rapid wear and shortened
assembly (22) and align with temporary marks. component life.
7. Tighten hose clamps (19) to a torque of 11 N·m
(97 lb in). Ensure that the hose clamps are
correctly orientated.
UENR4544 61

assemblies can be installed as an assembly or the
turbocharger compressor outlet tube assemblies
can be installed individually. For removal of
individually section all or part of this installed
procedure can be used.

install bracket (14), bracket (15), and bracket (17).
a. Align temporary marks and install bracket (17)

onto cam follower housing. Install bolts (18)
hand tight.
b. Align temporary marks and install bracket

(15). Install nuts and bolts (16) hand tight.
c. Align temporary marks and install bracket (14)

onto the back plate. Install nuts and bolts (13)
hand tight
62 UENR4544
7. Slide hose assembles (4) backward along tube

assembly (2). Position a new gasket (5) (not
shown) between tube assembly (2) and tube
assembly (8).
8. Install nuts and bolts (6) and nuts and bolts (7)
hand tight. Ensure that the different length bolts
are installed into the correct position.
9. Tighten nuts and bolts (6) and nuts and bolts (7) to
10. Tighten nuts and bolt (3) to a torque of 50 N·m
(35 lb ft).
(35 lb ft).
14. Tighten hose clamps (3) hose clamps (11) to a
torque of 11 N·m (97 lb in). Ensure that the hose
clamps are correctly orientated.
4. Apply Tooling (A) to inner section of hose
assembly (12). Ensure hose clamps (11) are
5. Install tube assembly (8) to hose assembly (12).
6. Install clamp (10) to tube assembly (8). install nuts
(9) hand tight.
UENR4544 63
Exhaust Manifold Front for Cylinder One

and Two and Center Section
15. Install heat shield (1) from the hose assembly.

i06511746
1. Sufficiently loosen V-band clamp (5) to enable the

Exhaust Manifold - Remove V-band clamp to be removed.
and Install 2. Support exhaust manifold (3). Remove bolts (1)
and spacers (2).
3. Remove exhaust manifold (3) from the cylinder
Removal Procedure heads.
4. Remove gaskets (4) (not shown).
NOTICE
component life.
Note: Removal of individual sections of an exhaust

manifold is possible without removing the complete
exhaust manifold.

V-band clamp to be removed.
6. Remove nuts (8) from the clamp. Remove the
clamp from bracket (7).
64 UENR4544
7. Remove tube assembly (6) and remove V-band

clamp (9).
Exhaust Manifold for Cylinder Heads

Three, Four, Five, and Six
NOTICE
component life.

manifold is possible without removing the complete
exhaust manifold.
7. Sufficiently loosen V-band clamp (19) and V-band

clamp (20) to enable the V-band clamp to be
removed.
8. Support exhaust manifold (18). Remove bolts (22)
and spacers (21). Remove the exhaust manifold
from the cylinder heads.
10. Remove V-band clamp (19), V-band clamp (2),
and bellows (24).
1. Sufficiently loosen V-band clamp (12) and V-band

clamp (13) to enable the V-band clamp to be
removed.
2. Loosen nuts (8) to allow bracket (7) to rotate.
3. Remove nuts (11) and remove the clamp from
bracket (7). Rotate the bracket away from exhaust
manifold (10).
4. Support exhaust manifold (10). Remove bolts (16)
and spacers (15). Remove the exhaust manifold
from the cylinder heads.
6. Remove V-band clamp (12), V-band clamp (13),
and bellows (19).
UENR4544 65
Upper Section of the Rear Exhaust 2. If equipped, remove exhaust temperature sensor
Manifold (30) from exhaust manifold (26). Refer to
Disassembly and Assembly, “Engine Sensors -
(Exhaust Temperature Thermocouple) Remove
and Install” for the correct procedure.
3. Remove air cleaner (27). Refer to Disassembly
and Assembly, “Air Cleaner- Remove and Install”
4. Remove turbocharger (28) from exhaust manifold
(26). Refer to Disassembly and Assembly,
“Turbocharger - Remove” for the correct
procedure.
V-band clamp to be removed.
6. Remove bolts (31) and bolts (32) from exhaust
manifold (26). Remove the exhaust manifold.
7. Remove V-band clamp (25) from the exhaust
bellows.
Lower Section of the Rear Exhaust

Manifold
1. To remove the lower section of the rear exhaust
manifold, the removal of the upper section of the
rear exhaust manifold will need to be carried out.

and Assembly, “Exhaust Elbow - Remove and
Install” for the correct procedure.
66 UENR4544

3. If equipped, remove exhaust temperature sensor
(35) (not shown) from exhaust manifold (26). Refer
to Disassembly and Assembly, “Engine Sensors -
4. Remove turbocharger (34) from exhaust manifold
procedure.
5. Remove exhaust manifold (26) from exhaust
manifold (38). Refer to Disassembly and
Assembly, “Exhaust Manifold - Remove and Install
(Upper Section of the Rear Exhaust Manifold)” for
the correct procedure.
6. Remove bolts (42) and spacers (41) from exhaust
manifold (38). Remove the exhaust manifold.
8. Remove V-band clamp (37) from the exhaust
bellows.
UENR4544 67
Table 14
Required Tools

A - 1
Compound
NOTICE
component life.
Lower Section of the Rear Exhaust

Manifold
1. Ensure that the gasket surfaces of the exhaust
manifolds and the cylinder heads are clean and
free from damage. Ensure that the bellows are
clean and free from damage, replace any
2. Installation of individual sections of an exhaust
manifold is possible. Depending on what part of
the exhaust manifold was removed will depend on Illustration 128 g06010897
how the installation of the exhaust manifold is
carried out. Select the correct part of the
procedure to carry out the installation of the
exhaust manifolds.
68 UENR4544
11. Install turbocharger (34) from exhaust manifold

procedure.
12. Install exhaust elbow (29). Refer to Disassembly
13. If equipped, install exhaust temperature sensor
(35) (not shown) to exhaust manifold (26). Refer to

Typical example
3. Position new gaskets (40) (not shown) onto the

cylinder heads.
4. Apply Tooling (A) to the treads of V-band clamp
(37). Install the V-band clamp onto the exhaust
bellows. Ensure that the V-band clamp is correctly
orientated.
5. Apply Tooling (A) to the treads of bolts (42).
6. Position exhaust manifold (38) onto the cylinder
heads. Install bolts (42) and spacers (41) to the
exhaust manifold. Hand tighten the bolts. Ensure
that the exhaust manifold is correctly located onto
the exhaust bellows.
7. Position V-band clamp (37) onto exhaust manifold
(38) and the exhaust bellows. Hand tighten the V-
band clamp and ensure that the V-band clamp is
correctly located and aligned.
8. Install exhaust manifold (26) to exhaust manifold
“Exhaust Manifold - Remove and Install (Upper
Section of the Rear Exhaust Manifold)” for the
correct procedure.
(80 lb in).
a. Lightly tap the V-band clamps with a soft faced

hammer to seat the V-band clamp. Again,
tighten the V-band clamp to a torque of 9 N·m
(80 lb in). Repeat this Step 10.a until the V-
band clamp are secure and correctly seated.
UENR4544 69
Upper Section of the Rear Exhaust

Manifold

Typical example
1. Apply Tooling (A) to the treads of V-band clamp

(25). Install the V-band clamp onto the exhaust
bellows. Ensure that the V-band clamp is correctly
orientated.
2. Position exhaust manifold (26) onto lower section
of the rear exhaust manifold.
Illustration 131 g06010656 3. Tighten V-band clamp (25) hand tight. Ensure that
V-band clamp and exhaust manifold (26) are
correctly located onto the exhaust bellows.
4. Install bolts (31) and bolts (32) to exhaust manifold
(26). Hand tighten the bolts. Ensure that the
exhaust manifold is correctly aligned onto the
exhaust bellows.
58 N·m (43 lb ft).
(80 lb in).

hammer to seat the V-band clamp. Again,
7. Install turbocharger (28) to exhaust manifold (26).
Refer to Disassembly and Assembly,
Illustration 132 g06010661 procedure.
8. Install exhaust elbow (29). Refer to Disassembly
70 UENR4544
9. If equipped, remove exhaust temperature sensor

(30) from exhaust manifold (26). Refer to
10. Remove air cleaner (27). Refer to Disassembly
and Assembly, “Air Cleaner- Remove and Install”
Exhaust Manifold for Cylinder Heads

Three, Four, Five, and Six
NOTICE
component life.

manifold is possible without removing the complete Illustration 134 g06010575
exhaust manifold.


Typical example
2. Apply Tooling (A) to the treads V-band clamp (19)

and V-band clamp (20).
3. Position V-band clamp (20) onto the exhaust
manifold. Install bellows (24) and locate the V-
band clamp onto the bellows. Position V-band
clamp (19). Ensure that the V-band clamps are
4. Position gaskets (23) (not shown) onto the cylinder
heads.
5. Apply Tooling (A) to the treads bolts (22).
UENR4544 71

7. Position V-band clamp (19) onto exhaust manifold
(18).
8. Hand tighten V-band clamp (19) and V-band clamp
(20). Ensure that the exhaust manifold is correctly
aligned onto the exhaust bellows.
10. Tighten V-band clamp (19) and V-band clamp
(20) to a torque of 9 N·m (80 lb in).

band clamps are secure and correctly seated. Illustration 136 g06010527

Typical example
11. Apply Tooling (A) to the treads V-band clamp (12)

and V-band clamp (13).
12. Position V-band clamp (13) onto the exhaust
manifold. Install bellows (19) and locate the V-
band clamp onto the bellows. Position V-band
clamp (12). Ensure that the V-band clamps are
13. Apply Tooling (A) to the treads bolts (16).
14. Position gaskets (14) (not shown) onto the
cylinder heads.
72 UENR4544

16. Position V-band clamp (12) onto exhaust
manifold (10).
17. Hand tighten V-band clamp (12) and V-band
clamp (13). Ensure that the exhaust manifold is
correctly aligned onto the exhaust bellows.
19. Tighten V-band clamp (12) and V-band clamp
(13) to a torque of 9 N·m (80 lb in). Illustration 138 g06010483

band clamps are secure and correctly seated.
20. Rotate bracket (7) onto exhaust manifold (10).
Install clamp to bracket (7) and install nuts (11).
21. Tighten nuts (8) and nuts (11) to a torque of
44 N·m (32 lb ft).
Exhaust Manifold Front for Cylinder One

and Two and Center Section
UENR4544 73
band clamps are secure and correctly seated.
i06511747
Exhaust Elbow - Remove and

Install
Removal Procedure
NOTICE
component life.

Typical example
2. Apply Tooling (A) the threads V-band clamp (9).

Position the V-band clamp onto the exhaust
manifold. Ensure that the V-band clamp is
correctly orientated
3. Install tube assembly (6) onto the exhaust
manifold. Install V-band clamp (9). Hand tighten
the V-band clamp.
4. Install the clamp to bracket (7) and install nuts (8).
Hand tighten the nuts.
5. Apply Tooling (A) the threads of V-band clamp (5).
Position the V-band clamp onto the tube assembly
(6). Ensure that the V-band clamp is correctly
orientated
6. Apply Tooling (A) the threads of bolts (1).
7. Position gaskets (4) (not shown) onto the cylinder
heads.
heads. Install bolts (1) and spacers (2). hand
tighten the bolts. Illustration 141 g06011029
9. Tighten bolts (1) to a torque of 58 N·m (43 lb ft). 1. Remove the Original Equipment Manufacture
10. Tighten V-band clamp (9) and V-band clamp (5) (OEM) exhaust system (1) from exhaust elbow (5).
to a torque of 9 N·m (80 lb in). 2. If equipped with an exhaust temperature sensor.
Remove exhaust temperature sensor (4) from
a. Lightly tap the V-band clamps with a soft faced exhaust elbow (7). Refer to OEM for the correct
hammer to seat the V-band clamps. Again, procedure.
(80 lb in). Repeat this Step 10.a until the V- 3. Attach a suitable lifting equipment to support
exhaust elbow (5). The weight of the exhaust
elbow is approximately 35 kg (77 lb).
74 UENR4544
4. Sufficiently loosen V-band clamps (3) and V-band Installation Procedure

clamps (8) for exhaust bellow (2) and exhaust Table 15
bellows (9). Required Tools
5. Remove bolts (6) (not shown) and spacers (7) (not Tool Part Number Part Description Qty
shown). Use the suitable lifting equipment to
remove the exhaust elbow. Loctite C5-A Anti-Sieze
A - 1
Compound
6. Remove V-band clamps (3) and V-band clamps (8)
and exhaust bellow (2) and exhaust bellows (9).
NOTICE
component life.
1. Ensure that the exhaust elbow is clean and free

from damage. Ensure that the bellows are clean
and free from damage, replace any component
that is worn or damaged.

remove bracket (11).
a. Attach a suitable lifting equipment to support

bracket (11). The weight of the bracket is
b. Remove bolts (10) from bracket (11). Use the

suitable lifting equipment to remove the
bracket from bracket (12).
c. Remove the suitable lifting equipment from

bracket (11).
UENR4544 75

install bracket (11).
a. Attach a suitable lifting equipment to bracket

(11). The weight of the bracket is
b. Use the suitable lifting equipment to position

bracket (11) onto bracket (12)
c. Install bolts (10) to bracket (11). Hand tighten

the bolts.
3. Apply Tooling (A) to the threads of V-band clamp
(3) and V-band clamp (8).
4. Position one off V-band clamp (3) onto the
Seating the V-band clamp on the turbocharger turbocharger. Ensure that the V-band clamp is
correctly orientated. Position exhaust bellows (2)
onto V-band clamp (3). Hand tighten the V-band
clamp.
5. Position one off V-band clamp (8) onto the
turbocharger. Ensure that the V-band clamps are
correctly orientated. Position exhaust bellows (9)
onto V-band clamp (8). Hand tighten the V-band
clamp.
76 UENR4544
6. Install the remaining V-band clamp (3) and Note: Removal of individual sections of an inlet
remaining V-band clamp (8) onto exhaust bellow manifold without removing the complete manifold is
(2) and exhaust bellow (9). Ensure that both V- possible. If removal of a complete manifold is
band clamps are correctly orientated. necessary, use a suitable lifting device.
7. Attach a suitable lifting equipment to support Front Section of the Inlet Manifolds
exhaust elbow (5). The weight of the exhaust
elbow is approximately 35 kg (77 lb).
8. Use the suitable lifting equipment to install exhaust
elbow (5) onto the bracket.
9. Install V-band clamp (3) and V-band clamp (8) onto
exhaust elbow (5). Hand tighten the V-band
clamps.
10. Apply Tooling (A) to the threads of bolts (6) (not
shown).
11. Install bolts (6) (not shown) and spacers (7) (not
shown) exhaust elbow (5). hand tighten the bolts.
12. Tighten bolts (6) (not shown) to a torque of
58 N·m (43 lb ft).
(80 lb in).

hammer to seat the V-band clamp. Again, Illustration 146 g06006478
15. Remove the suitable lifting equipment from
exhaust elbow (5).
16. Install the OEM exhaust system (1) to exhaust
elbow (5).
17. If equipped with an exhaust temperature sensor.
Install exhaust temperature sensor (4) to exhaust
elbow (7). Refer to OEM for the correct procedure.
i06511740
Inlet Manifold - Remove

Removal Procedure
NOTICE
Contaminants may cause rapid wear and shortened 1. Remove nuts and bolts (3) from connection (6).
component life.
2. Loosen hose clamps (7) and slide the connection
away from inlet manifold (2). Remove gasket (5)
(not shown).
3. Remove nuts and bolts (1).
UENR4544 77
4. Support inlet manifold (2). Remove bolts (8) from Inlet Manifold Center Sections
the inlet manifold.
5. Remove inlet manifold (2) from the cylinder heads.
Remove gaskets (9) (not shown).
6. Remove O-ring seal (4) (not shown) from inlet
manifold (10).
1. Remove the bracket for governor (17). Refer to

Disassembly and Assembly, “Governor - Remove”
78 UENR4544
2. Remove nuts and bolts (11) nuts and bolts (13), Inlet Manifold Rear Section
and nuts and bolts (15) from inlet manifold (12)
inlet manifold (14), and inlet manifold (10).
3. Remove bolts (10) from the bracket for the
electronic control unit on inlet manifold (4).
Remove electronic control unit (11) from the inlet
manifold and position the electronic control unit
away from the inlet manifold.
4. Support inlet manifold (12) inlet manifold (14) and
remove bolts (20) and bolts (22). Remove the inlet
manifolds from the cylinder heads.
5. Remove O-ring seal (16) (not shown).O-ring seal
(18) (not shown), and O-ring seal (19) (not shown)
from inlet manifold (12) inlet manifold (14).
6. Remove gasket (21) (not shown) and gasket (23)
(not shown).
1. Removal of air cleaners (24) and bracket (25) will

be required to remove rear section of the inlet
manifold. Refer to Disassembly and Assembly, “Air
Cleaner - Remove and Install” for the correct
procedure.
2. Remove nuts and bolts (28) from inlet manifold
(29).
3. Support inlet manifold (29) and remove bolts (26).
Remove the inlet manifold from the cylinder
heads.
UENR4544 79
4. Remove gaskets (27) (not shown). Remove O-ring

seal (30) (not shown) from inlet manifold (29).
i06511741
Inlet Manifold - Install

NOTICE
component life.
Note: Installation of individual sections of an inlet

manifold without removing the complete manifold is
possible. If Installation of a complete manifold is
necessary, use a suitable lifting device.
Inlet Manifold Rear Section

1. Ensure that the gasket surfaces of the inlet
manifold and the cylinder heads are clean and free
from damage.
2. Position new gaskets (27) (not shown) on the

cylinder heads.
3. Install a new O-ring seal (30) (not shown) into the
recess of inlet manifold (29).
4. Install inlet manifold (29) onto the cylinder heads.
Install bolts (26) to the inlet manifold finger tight.
Ensure that gaskets (27) (not shown) and O-ring
seal (27) (not shown) remain correctly located.
5. Install nuts and bolts (28) to inlet manifold (29)
hand tight.
80 UENR4544

(35 lb ft).
Inlet Manifold Center Sections

1. Ensure that the gasket surfaces of the inlet
free from damage.
2. Position new gaskets (21) (not shown) and new

gaskets (23) (not shown) onto the cylinder heads.
3. Install new O-ring seal (16) (not shown) to the
recess of the rear inlet manifold section.
UENR4544 81
4. Install new O-ring seal (18) (not shown), and new Front Section of the Inlet Manifolds
O-ring seal (19) (not shown) to inlet manifold (12)
inlet manifold (14).
Ensure that gaskets (23) (not shown), O-ring seal
(18) (not shown), and O-ring seal (19) (not shown)
remain correctly located.
7. Install nuts and bolts (11) nuts and bolts (13) and
nuts and bolts (15) to the inlet manifolds hand
tight.Do not install the nuts and bolts for
governor (17) bracket to the inlet manifolds.
10. Tighten nuts and bolts (11) nuts and bolts (13),
and nuts and bolts (15) to a torque of 47 N·m Illustration 156 g06006487
(35 lb ft).
11. Install the bracket for governor (17). Refer to
Disassembly and Assembly, “Governor - Remove”
1. Position new gaskets (9) (not shown) onto the

cylinder heads.
2. Install new O-ring seal (4) (not shown) to the
recess of inlet manifold (10).
82 UENR4544
4. Install nuts and bolts (11) to inlet manifolds (2) Note: Do not stamp the heads of the valves.
hand tight. Stamping or punching the heads of the valves could
cause the valves to fracture.
(35 lb ft).
7. Slide connection (6) towards inlet manifold (2). parts propelled by a released spring force.
Position new gasket (5) (not shown) between the
connection and the inlet manifold. Make sure to wear all necessary protective
equipment.
8. Install nuts and bolts (3) to connection (6) hand
tight. Tighten the nuts and bolts to a torque of recommended tooling to release the spring force.
47 N·m (35 lb ft).
9. Tighten hose clamps (7) securely to a torque of
7 N·m (62 lb in). NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
i06511693
Inlet and Exhaust Valves -

Remove and Install
Removal Procedure
Table 16
Required Tools
A T6253/243 Valve Spring Compressor 1
Start By:
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
NOTICE
Inlet, exhaust, valves, and valve seat on the 4008-
30 have a valve seat and valve angle of 20 degree.
For further information contact your Perkins
distributor.
NOTICE
component life.
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 Specifications, “Cylinder Head
Valves” for the correct dimensions.
2. Place a temporary identification mark on the heads
of the valves to identify the correct position.
UENR4544 83
Note: Valve stem seals are only installed on the inlet

valves.

remaining valves.
Table 17
Required Tools
A T6253/243 Valve Spring Compressor 1
NOTICE
component life.
1. Clean all components of the cylinder head

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

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

damage. Refer to Specifications, “Cylinder
Head Valves” for further information.
c. Inspect the valve guides for wear and for
damage. Refer to Specifications, “Cylinder
Head Valves” and Systems Operation, Testing
and Adjusting, “Valve Guide - Inspect” for
further information.
d. Inspect the valves for wear and for damage.
Refer to Specifications, “Cylinder Head
Valves”. Check the depth of the valve below
the face of the cylinder head. Refer to
Systems Operation, Testing and Adjusting,
“Valve Depth - Inspect” for more information.
e. Inspect the valve springs for the correct

length. Refer to Specifications, “Cylinder Head
Valves”.
3. Use Tooling (A) to compress the appropriate valve

spring (3). Remove valve collets (1).
4. Remove Tooling (A).
5. Remove cap (2). Remove valve spring (3).
6. Remove valve (5). Remove valve stem seals (4).
84 UENR4544
4. Use Tooling (A) to compress valve spring (3).

Install valve collets (1).

The valve spring keepers can be thrown from the
2. Install the new valve stem seals (4). Lubricate the valve when the valve spring compressor is re-
stem of valve (5) with clean engine oil. Install the leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre-
valve in the appropriate position in the cylinder vent personal injury, keep away from the front of
head. the valve spring keepers and valve springs dur-
ing the installation of the valves.
Note: Valve stem seals are only installed on the inlet
valves.
3. Install valve spring (3) to the cylinder head. 6. Repeat Step 2 through Step 5 to install the
Position cap (2) on the valve spring. remaining valves.
7. Place the cylinder head on a suitable support.
Ensure that the heads of the valves are not
Personal injury can result from being struck by obstructed. Gently tap the top of the valves with a
parts propelled by a released spring force. soft hammer to ensure that the valve collets are
correctly installed.
equipment.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
UENR4544 85
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i06511692
Inlet and Exhaust Valve Guides

- Remove and Install
Removal Procedure
Table 18
Required Tools
A - Valve Guide Removal Drift 1
Start By: Illustration 162 g06009494
a. Remove the inlet and exhaust valves. Refer to 1. Use Tooling (A) and a suitable press to push valve
Disassembly and Assembly, “Inlet and guides (1) out of the cylinder head.
Exhaust Valves - Remove and Install” for the
correct procedure.
NOTICE Table 19
Removal and installation of the valve guide and valve Required Tools
seat must be carried out by personnel with the correct
training. Also special machinery is required. For more Tool Part Number Part Description Qty
information, refer to your authorized Perkins
distributor. B T85002/3 Valve Guide Installation Tool 1
NOTICE NOTICE
Keep all parts clean from contaminants. Removal and installation of the valve guide and valve
seat must be carried out by personnel with the correct
Contaminants may cause rapid wear and shortened training. Also special machinery is required. For more
component life. information, refer to your authorized Perkins
distributor.
NOTICE
component life.
1. Ensure that the bores in the cylinder head for the

valve guides are clean and free from burrs or
carbon.
86 UENR4544
5. Check the installed height of each valve guide.

Dimension (X) should be 9 mm (0.354 inch).
Note: After installing the valve guides, the valve seat
inserts must be refaced. This procedure ensures the
concentricity of the valve seat to the valve guide to
create a good seal. Refer to Specifications, “Cylinder
2. Lubricate new valve guide (2) with clean engine oil. Head Valves” for more information. The valves must
Position the valve guide in the cylinder head. not be lapped into the seats with grinding paste.
Carefully tap the valve guide with a soft faced The abrasive particles are retained in the faces of
hammer to locate the valve guides in the cylinder the valve and the valve seat. The Abrasive
head. Ensure that the valve guide is located particles retained in the faces of the valves and
squarely in the cylinder head. the valves seat will cause rapid wear.
Note: Replacement valve guides are supplied, 6. Check the depths of the valves below the face of
finished to the correct size. the cylinder head. Refer to System Operation,
Testing and Adjusting, “Valve Depth - Inspect” for
3. Use Tooling (B) and a suitable press to install the more information.
valve guide to the cylinder head. Press the valve
guide until Tooling (B) bottoms out on the cylinder End By:
head. a. Install the inlet valves and the exhaust valves.
Refer to this Disassembly and Assembly
Note: The counterbore in Tooling (B) ensures that Manual, “Inlet and Exhaust Valves - Remove
the valve guide is installed to the correct height. and Install” for the correct procedure.
4. Repeat Step 2 and Step 3 to install the remaining i06510362
valve guides.
Engine Oil Filter Base -
Remove
Removal Procedure
Table 20
Required Tools
A - Strap Wrench 1
UENR4544 87
NOTICE
component life.
NOTICE
Care must be taken to ensure that fluids are con-
Be prepared to collect the fluid with suitable contain-
and mandates. Illustration 165 g01808193
1. If the engine oil filter base is equipped with an oil

pressure switch, disconnect the harness assembly
from the oil pressure switch.
2. Use Tooling (A) to remove engine oil filters (1) from

engine oil filter base (2). Refer to Operation and
Maintenance Manual, “Engine Oil and Filter
Change” for the correct procedure.
3. Remove bolts from tube clips (3) and clip (5).
Remove tube clips (3) and clip (5) from tube
assembly (3).
4. Disconnect tube assembly (4) from engine oil filter
base (2).
88 UENR4544

pressure switch (11) remove oil pressure switch
(11) from engine oil filter base (2).
i06510369
Engine Oil Filter Base - Install
Table 21
Required Tools
Guide Stud
B - 2
M10 by 75 mm
NOTICE
5. Remove bolts (7) from tube assembly (6). component life.
6. Remove O-ring seal (8) (not shown) from tube
assembly (6). 1. Ensure that all components of the engine oil filter
base are clean and free from damage. Ensure that
all oil passages are free from restriction. Clean the
gasket surface of the cylinder block.
7. Remove bolts (9) from engine oil filter base (2).

Remove engine oil filter base (2) from the engine
cylinder block.
UENR4544 89

pressure switch (11) install oil pressure switch (11)
to engine oil filter base (2). Tighten oil pressure
switch (11) securely.
3. Install new O-ring seal (8) (not shown) to tube
assembly (6).
4. Install a new gasket (10) (not shown).
Note: Ensure the correct orientation of the gasket.
5. Install engine oil filter base (2) onto the engine

cylinder block and install bolts (9) hand tight.
Remove Tooling (B) and install the remaining
bolts.
Illustration 170 g01808454 6. Install bolts (10) to tube assembly (8) hand tight.
90 UENR4544
10. Install bolts to tube clip (5) and clips (3) to tube
assembly (3). Tighten bolts for the tube clips
securely.
11. Install new engine oil filters (1) to engine oil filter
base (2). Refer to Operation and Maintenance
The bolt tightening sequence for the engine oil filter Manual, “Engine Oil and Filter Change” for the
base
correct procedure.
7. Tighten bolts (7) for tube assembly (8) to a torque 12. If the engine oil cooler is equipped with an oil
of 47 N·m (35 lb ft). Tighten the bolts in the pressure switch, connect the harness assembly to
sequence that is shown in Illustration 172 . the oil pressure switch.
8. Tighten bolts (9) for engine oil filter base (2) to a
i06510370
torque of 47 N·m (35 lb ft). Tighten the bolts in the
sequence that is shown in Illustration 172 . Engine Oil Cooler - Remove
Removal Procedure
NOTICE
component life.
NOTICE
and mandates.
9. Connect tube assembly (4) to engine oil filter base

(2). Tighten tube assembly securely.
UENR4544 91

Typical example
1. Drain the coolant from the cooling system into a

suitable container. Refer to Operation and
Maintenance Manual, “Cooling System Coolant -
Change” for the correct procedure. Open tap (2) Illustration 176 g01810005
and drain the coolant from engine oil cooler (1).
2. Remove bolts (4) and bolts (6). Remove tube

assembly (5) from engine oil cooler (1). Remove
O-ring seal (3) (not shown) and O-ring seal (7) (not
shown).
assembly (10) and remove O-ring seal (12) (not
shown) and gasket (8) (not shown).
4. Remove valve (13) and gasket (14) (not shown).
92 UENR4544
8. Use a suitable lifting device to support the weight

of engine oil cooler (1). The weight of the engine
oil cooler is approximately 45 kg (100 lb).
9. Remove bolts (25) and bolts (26) from engine oil
cooler (1).
10. Carefully pry engine oil cooler (1) from the dowels
on the cylinder block. Use the suitable lifting
device to remove engine oil cooler (1) from the
cylinder block.
5. Loosen hose clamps (19). Remove bolts (16).

Remove tube assembly(18) from engine oil cooler
(1). Remove gasket (17) (not shown).
6. Remove hose assembly (15) from engine oil cooler
(1). 11. If necessary, remove connection (28) from engine
oil cooler (1). Follow Step 11.a through Step 11.c
7. Remove nuts and bolts (21). Remove bolts (23).
to remove the connection.
Remove elbow (22) from the engine oil cooler.
Remove gasket (20) (not shown) and gasket (24) a. Remove bolts (27).
(not shown).
b. Remove connection (28) from engine oil
cooler (1).
UENR4544 93
c. Remove O-ring seal (29) (not shown).

NOTICE
12. Drain the oil from the engine oil cooler into a Care must be taken to ensure that fluids are con-
suitable container. nance, testing, adjusting and repair of the product.
and mandates.
13. Remove bolts (30). Remove bracket (32) from

engine oil cooler (1). Do not remove dowel pins
(34).
Note: Mark the position of the bracket for installation
purpose. Illustration 183 g01811721
14. Remove bolts (31). Remove bracket (33) from 1. Remove bolts (1) and bolts (5). Remove cover (2)
engine oil cooler (1). Do not remove dowel pins and cover (6) from the engine oil cooler.
(34).
Note: If necessary, tap the covers with a soft faced
Note: Mark the position of the bracket for installation hammer to loosen the covers.
purpose.
2. Remove O-ring seal (3). Remove gasket (4) (not
i06510371 shown).
Engine Oil Cooler -

Disassemble
Disassembly Procedure
Start By:
a. Remove the engine oil cooler. Refer to
Disassembly and Assembly, “Engine Oil
Cooler - Remove” for the correct procedure.
NOTICE
component life. 3. Carefully tap the rear face of tubestack (8) with a
soft faced hammer to drive the tubestack from the
housing of the engine oil cooler.
Note: Use a block of wood to protect the tubestack.
94 UENR4544
4. Remove gasket (7).
i06510372
Engine Oil Cooler - Assemble

Assembly Procedure
NOTICE
component life.
1. Ensure that all parts of the engine oil cooler are

clean and free from damage.
Note: If the tubestack is still contaminated with

limescale or with sludge after cleaning, then the
tubestack must be replaced. Do not use a
contaminated tubestack. The use of a contaminated
tubestack could lead to engine failure.
2. Place a new gasket (7) in position and push

tubestack (8) into the housing of the engine oil
cooler.
3. Place a new joint (4) (not shown) in position and
install cover (6).
4. Install bolts (5). Tighten the bolts to a torque of
40 N·m (30 lb ft).
5. Place a new O-ring seal (3) in position and install
cover (2).
40 N·m (30 lb ft).
7. Pressure test the engine oil cooler for leaks. Refer
to Systems Operation, Testing and Adjusting,
“General Information - Cooling System” for the
correct procedure.
UENR4544 95
End By:
a. Install the engine oil cooler. Refer to
Cooler - Install” for the correct procedure.
i06510373
Engine Oil Cooler - Install
Table 22
Required Tools

4. If necessary, Install connection (28) to engine oil
Guide Stud
A - 2 cooler (1). Follow Step 4.a through Step 4.b to
M10 by 75 mm
install the connection.
a. Install a new O-ring seal (29) (not shown) to
NOTICE connection (28).
Contaminants may cause rapid wear and shortened b. Install connection (28) to engine oil cooler (1).
component life. Install bolts (27) and tighten the bolts to a
1. Ensure that the engine oil cooler and the pipes are
clean and free from damage or restrictions.
2. Install bracket (32) to engine oil cooler (1). Bracket

(32) should be correctly positioned onto dowel
pins (34). Install bolts (30). Tighten the bolts to a
3. Install bracket (33) to engine oil cooler (1). Bracket
(33) should be correctly positioned onto dowel
pins (34). Install bolts (31). Tighten the bolts to a
96 UENR4544
5. Install Tooling (A) to the cylinder block. 11. Install Tooling (A) to the cylinder block.
6. Attach a suitable lifting device to engine oil cooler 12. Install a new gasket (14) (not shown) and install
(1). The weight of the engine oil cooler is valve (13).
7. Use a suitable lifting device to position engine oil
cooler (1) onto Tooling (A). Align the engine oil
cooler with the dowel pins in the cylinder block and
install the engine oil cooler to the cylinder block.
8. Install bolts (25) and bolts (26) to engine oil cooler
(1).
9. Remove Tooling (A) from the cylinder block. Install
remaining bolts (25) and bolts (26) to engine oil
cooler (1).
47 N·m (35 lb ft).
UENR4544 97
13. Install a new gasket (8) (not shown) to valve (13).

14. Install a new O-ring seal (12) (not shown) to tube
assembly (10). Install tube assembly (10) to
Tooling (A).
15. Install bolts (11) finger tight. Remove Tooling (A)
and install bolts (9) finger tight.
new O-ring seal (7) (not shown) to tube assembly
(5).
17. Install tube assembly (5) to engine oil cooler (1).
Install bolts (4) and bolts (6) finger tight.
21. Position gasket (24) (not shown) on the engine oil

cooler. Position gasket (20) (not shown) on elbow
(22).
22. Position elbow (22) on the engine oil cooler and
install nuts and bolts (21) hand tight. Install bolts
(23) hand tight. Tighten nuts and bolts (16) to a
Tighten bolts (23) to a torque of 47 N·m (35 lb ft).
98 UENR4544
23. Position a new gasket (17) (not shown) onto tube

engine oil cooler (1) and onto the elbow on the
water pump. Install bolts (16) hand tight. Tighten
hose clamps (18) securely. Tighten bolts (16) to a
24. Install hose assembly (15) to engine oil cooler (1)
and tighten securely.
25. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
Manual, “Cooling System Coolant - Change” for
26. Ensure that the engine oil pan is filled to the
correct level. Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check” for the correct
procedure.
i06510374
Engine Oil Relief Valve - Illustration 196 g01811853
Remove and Install

(Engine Oil Pressure Regulator) Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are
Removal Procedure removed.
NOTICE Be prepared to hold spring loaded covers as the

Keep all parts clean from contaminants. bolts are loosened.
Contaminants may cause rapid wear and shortened 1. Carefully loosen bolts (6). Remove the bolts and
component life. remove plate (5).
Note: The spring force will be released suddenly
NOTICE when the bolts are removed.
tained during performance of inspection, mainte- 2. Remove spring seat (2) and spring (4).
Be prepared to collect the fluid with suitable contain- 3. Remove plunger (1).
bling any component containing fluids. 4. Remove gasket (3).
Dispose of all fluids according to local regulations Installation Procedure

and mandates. Table 23
Required Tools
Bolts
- 2
A M8 by 50 mm
- Nuts M8 2
UENR4544 99
NOTICE
component life.
1. Ensure that all components of the engine oil

pressure regulator are clean and free from
damage.
Improper assembly of parts that are spring

loaded can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
2. Lubricate plunger (1) with clean engine oil. Install

the plunger and spring (4) into the bore for the
relief valve in the engine oil pump.
Note: The plunger must slide freely in the bore.
3. Place spring seat (2), gasket (3) and plate (6) into
position. Use Tooling (A) to hold the plate
temporarily in place. Refer to Illustration 198 .
Using of temporary nuts and bolts to install the
plate to the engine oil pressure regulator.
4. Tighten the nuts on Tooling (A) evenly to compress
spring (4).
5. Remove one nut and bolt from Tooling (A). Install
bolt (6) hand tight. Remove the remaining nut and
bolt from Tooling (A). Install the remaining bolt (6).
100 UENR4544
7. Run the engine to carry out final adjustment of the

engine oil pressure regulator. Refer to Systems
Operation, Testing and Adjusting, “General
Information - Lubrication System” for the correct
procedure.
i06510375
Engine Oil Relief Valve -

Remove and Install
(Engine Oil Cooler)
Removal Procedure
NOTICE
component life. Illustration 199 g01821493
NOTICE
and mandates.

assembly (5) from engine oil cooler (1). Remove
O-ring seal (3) (not shown) and O-ring seal (7) (not
shown).
assembly (10) and remove O-ring seal (12) (not
shown) and gasket (8) (not shown).
3. Remove valve (13) and gasket (14) (not shown).
UENR4544 101
(Table 24, contd)

Loctite 542 Hydraulic Thread
A - 1
Sealant
Guide Stud
B - 2
M10 by 75 mm
NOTICE
component life.
1. Ensure that all the components of the oil relief

valve are clean and free from damage.
Personal injury can result from parts and/or cov-

removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

remove the components from the assembly of
valve (13).
a. Remove plug (15) from the assembly of valve Illustration 202 g01821553
(13).
Note: The spring force will be released when the

plug is removed. Personal injury can result from parts and/or cov-
b. Remove sealing washer (16) from plug (15).
c. Remove spring (17) from the assembly of removed.
valve (13). Be prepared to hold spring loaded covers as the
bolts are loosened.
d. Remove plunger (18) from the assembly of
valve (13). 2. If necessary, follow Step 2.a through Step 2.d to
install the components to the assembly of valve
Installation Procedure (13).
Table 24
Required Tools a. Install plunger (18) to the assembly of valve
(13).
Note: The plunger must slide freely in the bore for
the relief valve.
(continued)
102 UENR4544
b. Install spring (17) to the assembly of valve

(13).
Note: Ensure that the spring is properly located
inside the plunger and the cap.
c. Install a new sealing washer (16) to plug (15).

Apply Tooling (A) to the threads of the plug.
d. Install plug (15) to the assembly of valve (13).

Tighten plug (15) to a torque of 25 N·m
(18 lb ft).
5. Install a new O-ring seal (12) (not shown) to tube

Tooling (B).

6. Install bolts (11) finger tight. Remove Tooling (B)
and install bolts (9) finger tight.
7. Install a new O-ring seal (3) (not shown) and a new
O-ring seal (7) (not shown) to tube assembly (5).
8. Install tube assembly (5) to engine oil cooler (1).
Install bolts (4) and bolts (6) finger tight.
10. Tighten bolts (4) and (6) to a torque of 40 N·m
(30 lb ft).
11. Ensure that the engine oil pan is filled to the
correct level. Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check” for the correct
procedure.
i06510376
Engine Oil Pump - Remove

Removal Procedure
3. Install Tooling (B) to the cylinder block. NOTICE

4. Install a new gasket (14) (not shown) and install
valve (13) onto Tooling (B). Contaminants may cause rapid wear and shortened
component life.
UENR4544 103
5. Place a suitable container below the engine oil

NOTICE
Care must be taken to ensure that fluids are con- pump. Remove bolts (4) from connection (3).
tained during performance of inspection, mainte- Allow the engine oil to drain into the suitable
nance, testing, adjusting and repair of the product. container.
ers before opening any compartment or disassem- Note: Cap all open ports and tube assemblies.
6. Remove O-ring seal (5) (not shown).
and mandates.

2. Drain the engine oil into a suitable container for
storage or disposal. Refer to Operation and
Change.” for the correct procedure.
7. Remove nut and washers (11) from fuel transfer

pump (8). Remove the fuel transfer pump from
engine oil pump (18).
9. Remove bolts (14) and bolts (17) from tube
assembly (15). Remove the tube assembly from
engine oil pump (18) and the engine oil pan.
10. Remove O-ring seal (13) (not shown) and O-ring
seal (16) (not shown).
3. Disconnect tube nut (1) and tube nut (6) for tube
fuel transfer pump (8) and the connection.
4. Disconnect tube nut (7) and tube nut (10) for tube
fuel transfer pump (8) and the fuel filter base.
104 UENR4544
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove” for the correct procedure.
NOTICE
component life.
NOTICE
and mandates.
Note: The overhaul of the engine oil pump is a

specialist operation that should only be attempted by
trained personnel with the correct equipment. A
service exchange engine oil pump is available from
your authorized Perkins distributor.
11. Remove bolts (19) and nuts (20).

12. Support the weight of engine oil pump (18). The
weight of the engine oil pump is approximately
32 kg (71 lb). Carefully slide the engine oil pump
along the retaining studs and remove the engine
oil pump.
i06510378
Engine Oil Pump -

Disassemble
Table 25
Required Tools Illustration 209 g06012567

1. Place the engine oil pump into a suitable holding
A - Combination Puller 1 device. The weight of the engine oil pump is
2. Use a suitable tool to hold gear (2). Ensure that the
gear is not damaged. Remove nut (4) and washer
(3).
UENR4544 105
3. Use Tooling (A) to pull gear (2) from the shaft of b. Place rear section (9) of engine oil pump (5).
engine oil pump (18). Remove key (21). Ensure that the gasket face of the engine oil
pump is not damaged. Use a suitable tool to
4. Remove key (1) from the shaft of engine oil pump
press the bush from the front section of the
(5).
engine oil pump.
i06510379
Engine Oil Pump - Assemble
Assembly Procedure
Table 26
Required Tools
Loctitie 542 Thread lock and

B - 1
Nut lock
- Bolts M10 by 200 mm 3

C - M10 Nuts 3
- M10 Flat Washers 6
Illustration 210 g06012569 NOTICE

5. Remove engine oil relief valve (18) from engine oil
pump (5). Refer to Disassembly and Assembly,
component life.
“Engine Oil Relief Valve -Remove and Install” for
Note: The overhaul of the engine oil pump is a
6. Place engine oil pump (5) into a suitable holding
specialist operation that should only be attempted by
device with body of engine oil pump (9) facing trained personnel with the correct equipment. A
upwards. The weight of the engine oil pump is service exchange engine oil pump is available from
approximately 32 kg (71 lb). your authorized Perkins distributor.
7. Remove rear section (9) from front section (19) of
1. Ensure that all components of the engine oil pump
are clean and free from wear or damage. Check
8. Remove gasket (3). the condition of the drive for the lift pump. Check
the clearance between the outer rotor of the oil
9. Remove outer rotor (12) from front section (19) of
pump and the oil pump body. Check the clearance
between the outer rotor and the inner rotor. Check
10. Remove inner rotor (15) from front section (19) of the end play of the rotors. Refer to the
engine oil pump (5). Specifications, “Engine Oil Pump” for more
information.
11. If necessary, remove shaft (14) from inner rotor
(15). Remove key (13) from the shaft.
12. If necessary, follow Step 12.a through Step 12.b
to remove bush (10) and bush (16) front section
(19) and rear section (9) of engine oil pump (5).
a. Place front section (19) of engine oil pump (5)

on a suitable press. Ensure that the gasket
face of the engine oil pump is not damaged.
Use a suitable tool to press the bush from the
front section of the engine oil pump.
106 UENR4544

2. If necessary, follow Step 2.a through Step 2.f to
install bush (10) and bush (16) front section (19)
and rear section (9) of engine oil pump (5).
a. Place front section (19) of engine oil pump (5)

b. Correctly align a new bush (6) into front

section (19) of engine oil pump (5). Ensure
that oil holes are correctly aligned.
c. Use a suitable tool to press bush(16) into front

section (19) of engine oil pump (5).
d. Place rear section (9) of engine oil pump (5)

e. Correctly align a new bush (10) into rear

section (19) of engine oil pump (5). Ensure
that oil holes are correctly aligned.
f. Use a suitable tool to press bush(10) into rear
section (9) of engine oil pump (5).
install inner rotor (15) to shaft (14).
a. Install key (13) to shaft (14). Ensure that the

key is correctly seated in to the shaft.
b. Install rotor (15) onto shaft (14). Align the rotor

with key (13). Use a suitable press to install
the rotor onto the shaft. Ensure that the rotor is
installed up to Shoulder (W).
UENR4544 107
4. If necessary, install dowels (17) to front section

(19) of engine oil pump (5).
5. Lubricate the assembly shaft (14), inner rotor (15),
and bush (16).
6. Install shaft (14) and inner rotor (15) to front
section (19) of engine oil pump (5). Ensure that the
shaft rotates freely in the bush (16).
7. Lubricate outer rotor (12). Install the outer rotor to
front section (19) of engine oil pump (5). Ensure
shaft (14) and the outer rotor rotates freely.
NOTICE
The end play of the engine oil pump is controlled by
the gasket. Always assemble a new POWERPART
joint to the engine oil pump. Failure to use a new
POWERPART gasket may result in serious damage
to the engine.
8. Position a new gasket onto front section (19) of

engine oil pump (5). Ensure that the gasket is Illustration 214 g06012567
14. Place the engine oil pump into a suitable holding
9. Position rear section (9) onto front section (19). device. The weight of the engine oil pump is
Ensure that shaft (4) correctly locates into bush approximately 32 kg (71 lb).
(10).
15. Install key (1) to the shaft of engine oil pump (5).
10. Align the bolt holes in rear section (9) with front Ensure that the key is correctly seated in to the
section (19) shaft.
11. If engine oil pump (5) is not to be install 16. Install gear (2) from the shaft of engine oil pump
immediately, install Tooling (C) to engine oil pump (5).
(5). Tighten the nuts for Tooling (C) hand tight.
17. Apply Tooling (B) to the thread of the shaft. Install
12. Ensure that shaft (14) of engine oil pump (5) is washer (3) and nut (4).
free to rotate.
18. Use a suitable tool to hold gear (2). Tighten nut
13. Install engine oil relief valve (18) to engine oil (4) to a torque of 237 N·m (175 lb ft). Ensure that
pump (5). Refer to Disassembly and Assembly, the gear is not damaged. Ensure the shaft of
“Engine Oil Relief Valve -Remove and Install” for engine oil pump (5) is free to rotate.
End By:
a. Install the engine oil pump. Refer to
- Install” for the correct procedure.
i06510380
Engine Oil Pump - Install
Table 27
Required Tools

Loctite 542 Thread lock and
B - 1
Nut lock
108 UENR4544
NOTICE
component life.
1. Ensure that the engine oil pump is clean and free

from damage. Ensure that the tube assemblies are
clean and free from restriction.
UENR4544 109

12. Position a new gasket (12) (not shown) onto
13. Install fuel transfer pump (8) onto engine oil pump
(18). Ensure that the fuel transfer pump is correctly
orientated.
14. Install nut and washers (11) to fuel transfer pump
(8). Tighten the nuts to a torque of 25 N·m
(18 lb ft).
2. Position a new gasket (21) (not shown) onto the

back plate.
3. Attach a suitable lifting equipment on to engine oil
pump (18). The weight of the engine oil pump is
4. If necessary, retaining bolts from the engine oil
pump (18).
5. Lubricate the gear of the engine oil pump with
clean engine oil. Use the suitable lifting equipment
to install engine oil pump (18). Carefully slide the
engine oil pump along the retaining studs and
install the engine oil pump to the back plate.
6. Install bolts (19) and nuts (20). Hand tighten the
nuts and the bolts.
new O-ring seal (16) (not shown) to tube assembly Illustration 217 g06012047
(15). Ensure that the O-ring seals a correctly
located into the recess of the tube assembly. 15. Remove cap from ports of the engine oil pump
and connection (3).
8. Apply Tooling (B) to threads of bolts (14).
16. Install O-ring seal (5) (not shown) to the recess of
9. Position tube assembly (15) onto engine oil pump
connection (3). Ensure that the O-ring seal is
(18) and the engine oil pan. Install bolts (14) and
correctly seated into the recess of the connection.
bolts (17) to the tube assembly. Hand tighten the
bolts. 17. Position connection (3) onto the engine oil pump.
Install bolts (4) hand tight. Tighten the bolts to a
10. Tighten bolts (19) and nuts (20) to a torque of
50 N·m (35 lb ft).
110 UENR4544
18. Install tube assembly (9) from fuel transfer pump

(8) and the fuel filter base. Tighten tube nut (7) and
tube nut (10) to a torque of 68 N·m (50 lb ft).
19. Install tube assembly (2) to fuel transfer pump (8)
and the connection. Tighten tube nut (1) and tube
nut (6) to a torque of 68 N·m (50 lb ft).
20. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter Change.” for the correct procedure.
21. Prime the engine oil system. Refer to Operation
and Maintenance Manual, “Before Starting the
Engine” for the correct procedure.
Operation and Maintenance Manual, “Before
Starting the Engine” for the correct procedure.
i06510381
Water Pump - Remove

Removal Procedure
NOTICE
component life.
NOTICE
and mandates.

3. Loosen the hose clamps and disconnect hose (7)
suitable container. Refer to Operation and
from elbow connection (4).
Maintenance Manual, “Cooling System Coolant -
Change” for the correct procedure. 4. Remove bolts (3) and remove connection (4) from
water pump (1). Remove gasket (6) (not shown).
2. If necessary, remove the alternator. Refer to
Disassembly and Assembly, “Alternator Remove 5. Loosen the hose clamps and loosen hose (2) from
and Install (Alternator Drive)” for more information. the elbow connection on water pipe (1).
6. Loosen hose clamp (9) on elbow connection (10).
Remove bolts (11) and remove elbow connection
(10) from water pump (1).
UENR4544 111
8. Remove bolts (8) and remove water pump (1).

Remove gasket (5) (not shown).
i06510392
Water Pump - Disassemble
Table 28
Required Tools
A - Circlip Pliers 1
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove” for the
correct procedure. Illustration 220 g01842553
NOTICE 1. Separate body (1) from bearing housing (5).

Note: If necessary, tap the body with a soft faced
Contaminants may cause rapid wear and shortened hammer to separate the body from the bearing
component life. housing.
2. Remove O-ring seal (3).

NOTICE
Care must be taken to ensure that fluids are con- 3. Mount gear (7) in a suitable bench vise to prevent
tained during performance of inspection, mainte- the shaft from rotating.
Be prepared to collect the fluid with suitable contain- Note: Ensure that the gear is protected by soft vise
ers before opening any compartment or disassem- jaws.
4. Remove nut (9) and washer (8). Remove gear (7)
Dispose of all fluids according to local regulations and remove the key from shaft (10).
and mandates.
5. Use Tooling (A) to remove circlip (12) from bearing
housing (5).
6. Position bearing housing (5) on a suitable support
with impeller (2) upward. Use a suitable mandrel
and a press to press the assembly of shaft (10)
and bearings (13) from the impeller and from the
bearing housing.
7. Remove carbon seal (11) from impeller (2).
Remove counterface (4) from bearing housing (5).
8. Remove seal (14) from bearing housing (5).
Remove the snap rings from the bearing housing.
Note: The snap rings retain the bearings in the

bearing housing.
9. Position the assembly of shaft (10) and bearings

(13) on a suitable support. Use a suitable mandrel
and a press to press the bearings from the shaft.
Remove spacer (6).
112 UENR4544
Note: Shims may be installed between the bearings

and the spacer.
i06510393
Water Pump - Assemble
Assembly Procedure
Table 29
Required Tools
A - Circlip Pliers 1

B - 1
Nut lock
C - 1
Grease
NOTICE 2. Place shaft (10) on a suitable support and press on

the inner race of bearing (13) until the bearing is
Contaminants may cause rapid wear and shortened against the shoulder of the shaft. Install spacer (6)
component life. to the shaft. Press on the inner race of second
bearing (13) until the bearing is against the spacer.
1. Ensure that the components of the water pump are Note: If shims were installed between the bearings,
clean and free from damage. install the shims before installing the second bearing.
Note: A repair kit for the water pump is available from 3. Install a new seal (14) to bearing housing (5).
your authorized Perkins Distributor. All components
Install the seal with the spring toward the bearings.
in the repair kit should be used when a water pump is
overhauled. Lubricate the lip of the seal with clean engine oil.
4. Install new snap rings to bearing housing (5).
Install the assembly of shaft (10) and bearings
(13) to the bearing housing. Use Tooling (A) to
install circlip (12).
5. Position the key on the shaft and install gear (7).
6. Apply Tooling (B) to the threads on shaft (10).
Install washer (8) and nut (9) to the shaft.
7. Mount gear (7) in a suitable bench vise to prevent
the shaft from rotating. Tighten the nut to a torque
of 230 N·m (175 lb ft).
Note: Ensure that the gear is protected by soft vise
jaws.
8. Lubricate counterface (4) with a solution of de-

mineralised water and 4% Cylam lubricant. Use
the tool that is supplied with the repair kit to install
the counterface to bearing housing (5).
Note: After the counterface has been installed, the
bearing housing should be left for ten minutes to
allow the Cylam lubricant to evaporate.
UENR4544 113
9. Lubricate the internal bore of carbon seal (11) with

a solution of de-mineralised water and 4% Cylam
lubricant. Position carbon seal (11) on shaft (10).
Use the tool that is supplied with the repair kit to
install the carbon seal to the shaft.
Note: After the carbon seal has been installed,

pressure should be maintained on the carbon seal for
ten minutes to hold the carbon seal in position
against the counterface until the Cylam lubricant has
evaporated.
10. Position bearing housing (5) on a suitable support

with gear (7) downward. Press impeller (2) onto
shaft (10). Press the impeller onto the shaft until
the face of the impeller is flush with the end of the
shaft.
Note: After the impeller has been installed, ensure
that the shaft is free to rotate and that the impeller is
concentric to the bearing housing.
11. Lubricate a new O-ring seal (3) with Tooling (C).
Install the O-ring seal to bearing housing (5).
12. Install body (1) to bearing housing (5).
Note: After the body has been installed, ensure that
the impeller is free to rotate without touching to the
body.
End By:
a. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Install” for the
correct procedure.
i06510394
Water Pump - Install
Table 30
Required Tools Illustration 223 g01841095

2. Install Tooling (A) to the timing case.
Guide Stud
A - 2
M10 by 100 mm Note: Install Tooling (A) to inner bolt holes for the
water pump.
NOTICE 3. Position a new gasket (5) (not shown) on the

Keep all parts clean from contaminants. timing case.
Contaminants may cause rapid wear and shortened 4. Lubricate the gear on water pump (1) with clean
component life. engine oil. Align the water pump with Tooling (A)
and install the water pump to the timing case.
1. Ensure that the water pump and the water pipe are
clean and free from damage. Clean the gasket
surface of the timing case.
114 UENR4544
Note: Ensure that the gear on the water pump is

NOTICE
aligned with the idler gear. Ensure that the water Care must be taken to ensure that fluids are con-
pump is correctly seated on the timing case. tained during performance of inspection, mainte-
5. Install bolts (8) hand tight. Remove Tooling (A) and Be prepared to collect the fluid with suitable contain-
install remaining bolts (8). ers before opening any compartment or disassem-
7. Position a new gasket (6) (not shown) onto water and mandates.
pump (1). Install elbow connection (4) and install
bolts (3).
8. Tighten bolts (3) to a torque of 47 N·m (35 lb ft). suitable container. Refer to Operation and
9. Install hose (7) onto the elbow connection and Maintenance Manual, “Cooling System Coolant -
tighten the hose clamps securely. Change” for the correct procedure.
10. Position gasket (12) (not shown) on water pump

(1).
11. Install elbow connection (10) to water pump (1)
and hose (2). Install bolts (11). Tighten the bolts to
12. Tighten hose clamps (9) and hose clamp for hose
(2) securely.
13. If necessary, install the alternator. Refer to
Disassembly and Assembly, “Alternator Remove
and Install (Alternator Drive)” for more information.
14. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.
i06510402
Water Temperature Regulator

Housing - Remove and Install
(Thermostat Housing)
Removal Procedure Illustration 224 g06019487
NOTICE 2. Loosen the hose clamp and disconnect hose (1)

Keep all parts clean from contaminants. from thermostat housing(6).
Contaminants may cause rapid wear and shortened 3. Disconnect the harness assembly from coolant
component life. temperature switch(2) (not shown).
4. Remove bolts (3) and nuts (8) from thermostat
housing(6).
5. Remove thermostat housing (6) from tube
assembly (11) and rail (5).
6. Remove O-ring seal (4) (not shown) and O-ring
seal (7) (not shown).
UENR4544 115

remove tube assembly (11). f. If necessary, remove studs (23) from
thermostat housing (6).
a. Loosen hose clamps (9) from hose assembly
(10). g. If necessary, remove coolant temperature
switch (2). Refer to Disassembly and
b. Remove tube assembly (11) from the water Assembly, Coolant Temperature Switch -
pump elbow. Remove and Install for the correct procedure.
h. Remove nuts (20) and remove adapter (19)
remove bracket (13) from the cylinder block.
from thermostat housing (6).
a. Support bracket (13) and remove bolts (12).
i. Remove gasket (21).
b. Remove bracket (13) from the cylinder block.
j. If necessary, remove studs (22) from
Table 31
Required Tools

A - 1
lock
NOTICE
component life.
1. Ensure that all components of the thermostat

housing are clean and free of wear or damage. If
necessary, replace any component that is worn or
damaged. Clean all gasket surfaces of the
thermostat housing.
9. If necessary, follow Step 9.a through Step 9.j to

disassemble thermostat housing (6).
a. Place thermostat housing (6) in a suitable

support.
b. Remove nuts (14) and remove cover (15) from

c. Remove gasket (16).
d. Remove bolts and washers (18) and remove

thermostats (17) and O-ring seals (17a).
e. If necessary, remove studs (24) from

116 UENR4544
g. If necessary, install studs (23) to thermostat

housing (6). Apply Tooling (A) to the threads of
the studs and install the studs to the
thermostat housing and securely tighten the
studs.
h. If necessary, install studs (24)to thermostat
studs.
i. Install new O-ring seals (17a) to the recess of
thermostat housing (6). Ensure that the O-ring
seals are correctly installed in to recesses of
the thermostat housing.
j. Install thermostats (17) to thermostat housing

(6). Install bolts and washers (18). Tighten the
bolts and washers to a torque of 47 N·m
(35 lb ft).
k. Position a new gasket (16) onto thermostat

housing (6).
l. Install cover (15) onto thermostat housing (6).

Install nuts (14). Tighten the bolts to a torque
of 25 N·m (221 lb in).
2. If necessary, follow Step 2.a through Step 2.l to

disassemble thermostat housing (6).
a. Check thermostats (17) for correct operation.

Refer to Systems Operation, Testing and
Adjusting, “Water Temperature Regulator -
Test” for the procedure to test the thermostats.
b. Place thermostat housing (6) in a suitable

support.
c. If necessary, install studs (22)to thermostat

studs.
d. Position a new gasket (21) onto thermostat
housing (6).
e. Install adapter (19) to thermostat housing (6).

Install nuts (20). Tighten the bolts to a torque
of 25 N·m (221 lb in).
f. If necessary, install coolant temperature

switch (2). Refer to Disassembly and
Assembly, Coolant Temperature Switch -
Remove and Install for the correct procedure.
install bracket (13) onto the cylinder block.
UENR4544 117
12. Fill the cooling system to the correct level. Refer

a. Position bracket (13) onto the cylinder block. to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct filling
b. Install bolts (12) to bracket (13). Support the procedure.
bracket as the bolts are installed.
i06510408
c. Tighten bolts (12) to a torque of 47 N·m
(35 lb ft).
Engine Support (Front) -
install tube assembly (11).
Remove and Install
(Back plate)
a. Install tube assembly (11) onto the water
pump elbow and bracket (13).
b. Align the bolt holes in tube assembly (11) with Removal Procedure
bracket (13). Tighten hose clamps (9) from
hose assembly (10) to a torque of 8 N·m Start By:
(71 lb in). a. Remove the engine oil pump. Refer to
5. Install a new O-ring seal (4) (not shown) to rail (5). Disassembly and Assembly, “Engine Oil Pump
Ensure that the O-ring seal is correctly installed - Remove” for the correct procedure.
into the recess of the rail. b. Remove the timing gears. Refer to
6. Install a new O-ring seal (7) (not shown) to Disassembly and Assembly, “Gear Group
(Front) - Remove” for the correct procedure.
thermostat housing (6). Ensure that the O-ring
seal is correctly installed into the recess of the NOTICE
thermostat housing. Keep all parts clean from contaminants.
7. Install thermostat housing (6) to tube assembly Contaminants may cause rapid wear and shortened
(11) and rail (5). Ensure that the O-ring seals are component life.
not dislodged as the thermostat housing is
installed.
8. Install bolts (3) and nuts (8) to thermostat housing
(6). Hand tighten the bolts and the nuts.
10. Connect the harness assembly to coolant
temperature switch (2) (not shown).
11. Connect hose (1) to thermostat housing (6).
Tighten the hose clamps to a torque of 8 N·m
(71 lb in).

Typical example
1. Use a suitable hoist to lift the front of the engine.

The weight of the engine is approximately 3350 kg
(7385 lb).
118 UENR4544
Note: Ensure that the engine is adequately Installation Procedure

supported. Table 32
2. Attach a suitable lifting device to the back plate (1). Required Tools
The weight of the back plate is approximately Tool Part Number Part Description Qty
45 kg (100 lb).
Guide Studs
A - 2
3. Remove bolts (2). M10 by 100 mm
4. Use the suitable lifting device and remove back |B - Loctite 638 1
plate (1) from the crankcase.
5. Remove gasket (3) (not shown). NOTICE
component life.
1. Ensure that the gasket surface of the crankcase

and the back plate are clean.
2. Ensure that all components of the back plate and
the housing are free from wear or damage. If
necessary, replace any component that is worn or
damaged.

remove housing (4) from back plate (1).
a. Place back plate (1) onto a suitable press. Use

a suitable tool to remove housing (4) from the
back plate.
b. If necessary, use a suitable tool to remove

seal (6) form housing (4). Ensure that the
housing is not damaged as the seal is
removed. Illustration 230 g06019431
c. If necessary, use a suitable tool to remove 3. If necessary, follow Step 3.a through Step 3.d to
bush (5) form housing (4). Ensure that the remove housing (4) from back plate (1).
housing is not damaged as the bush is
removed. a. If necessary, use a suitable tool to install bush
(5) to housing (4). Ensure that the bush is
installed into the housing correctly.
UENR4544 119
10. Remove Tooling (A) from the crankcase.

b. If necessary, use a suitable tool to install seal
11. Install remaining bolts (2) to back plate (1). Hand
(6) to housing (4). Ensure that the seal is
tighten the bolts.
installed into the housing correctly.
c. Place back plate (1) onto a suitable press.
13. Remove excess material from gasket (3) (not
d. Apply Tooling (B) to out side of housing (4). shown). The gasket should be flush with the base
Use a suitable tool to install the housing to the of the backplate.
back plate. Ensure that the shoulder of the
14. Use a suitable hoist to lower the front of the
housing is installed up to the back plate.
engine. The weight of the engine is approximately
Note: Remove any excessive Tooling (B) from 3350 kg (7385 lb).
around the housing and the back plate. 15. Remove the suitable lifting devise from back plate
(1).
End By:
a. Install the timing gears. Refer to Disassembly
and Assembly, “Gear Group (Front) - Install”
b. Install the engine oil pump. Refer to
- Install” for the correct procedure.
i06510412
Flywheel - Remove
Removal Procedure
Table 33
Required Tools

Typical example Support Studs for Flywheel
A T6253/157 2
and Damper
4. Install Tooling (A) to Positions (X) on the Bolt M12 by 100mm
B - 2
crankcase.
5. Use a suitable hoist to lift the front of the engine.
The weight of the engine is approximately 3350 kg
(7385 lb).
Note: Ensure that the engine is adequately
supported.
6. Install a new gasket (3) (not shown). Ensure that

the gasket is correctly orientated.
7. Attach a suitable lifting device to the back plate (1).
The weight of the back plate is approximately
45 kg (100 lb).
8. Use the suitable lifting device and install back plate
(1) onto the crankcase.
9. Install bolts (2) to back plate (1). Hand tighten the
bolts.
120 UENR4544
Start By: a. Install a suitable bolt (1) to flywheel (4).

a. Remove the engine speed sensor. Refer to b. Position a suitable piece of wood (3) between
Disassembly and Assembly, “Engine Speed bolt (1) and the floor.
Sensor - (Engine Speed for Governor Control)
Remove and Install” for the correct procedure. 3. Loosen bolts (2). Remove two bolts (2) and install
Tooling (A) in place of the bolts. Remove
b. Remove the overspeed sensor. Refer to
Disassembly and Assembly, “Engine Speed remaining bolts (2).
Sensor - (Overspeed Sensor) Remove and 4. Install Tooling (B) into the threaded holes in
Install” for the correct procedure. flywheel (4). Tighten Tooling (B) evenly to push the
c. Remove the electric starting motor. Refer to flywheel off the crankshaft.
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct Note: Push the flywheel off the crankshaft until there
procedure. is sufficient clearance to install a suitable sling to the
flywheel.
NOTICE
component life.
1. Make a temporary mark to show the position of the

flywheel on the crankshaft.
5. Pass a suitable sling through the center of flywheel

(4). Attach the sling to a suitable lifting device and
support the weight of the flywheel. The weight of
the flywheel is approximately 160 kg (350 lb).
6. Continue to tighten Tooling (B) until the flywheel
Illustration 232 g01454176 has been pushed off the crankshaft.
7. Use the lifting device to remove flywheel (4).
8. Inspect the starter ring gear for wear or damage. If
necessary, follow Step 8 through Step 8.a to
remove the starter ring gear.
Note: Identify the orientation of the teeth on the

ring gear.
2. Follow Step 2.a and Step 2.b to prevent the

flywheel from rotating.
UENR4544 121
NOTICE
component life.
Always wear protective gloves when handling

parts that have been heated.
1. If the starting motor ring gear required

replacement, follow Step 1.a through Step 1.d to
Illustration 235 g01454182 install a new ring gear.
Typical example
a. Drill a hole through ring gear (5) between two

of the teeth.

Typical example
a. Lay flywheel (4) on a horizontal surface.

b. Identify the orientation of the teeth on new ring
Typical example
gear (5).
b. Use a hammer and a chisel to split ring gear Note: The chamfered side of the ring gear teeth
(5). Remove the ring gear from the flywheel. must face toward the starting motor when the
flywheel is installed.
i06510417
c. Heat ring gear (5) in an oven to a maximum
Flywheel - Install temperature of 250 °C (482 °F).
d. Ensure the correct orientation of ring gear (5)

and quickly install the ring gear to flywheel (4).
Installation Procedure Note: Ensure that the ring gear is seated on the
Table 34 shoulder of the flywheel.
Required Tools
2. Inspect the crankshaft rear seal for leaks. If there
Tool Part Number Part Description Qty are any oil leaks, replace the crankshaft rear seal.
Support Studs for Flywheel
Refer to Disassembly and Assembly, “Crankshaft
A T6253/157 2 Rear Seal - Remove and Install” for the correct
and Damper
procedure.
Loctite C5-A Anti-Seize
C - 1
Compound
122 UENR4544
3. Pass a suitable sling through the center of flywheel

(4). Attach the sling to a suitable lifting device and
support the weight of the flywheel. The weight of
the flywheel is approximately 160 kg (350 lb).
4. Install Tooling (A) to the crankshaft.
5. Use the lifting device to position flywheel (4) onto
Tooling (A).
Note: Ensure the correct orientation of the flywheel.

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

flywheel (4).
7. Apply Tooling (C) to the threads of bolts (2). Apply
Tooling (C) to the underside of the heads of bolts
(2). Install bolts (2) to flywheel (4). Tighten the
bolts evenly to pull the flywheel onto the
crankshaft. Illustration 240 g01926062
8. Remove Tooling (A) and install the remaining bolts The tightening sequence for the flywheel bolts
(2) hand tight.
9. Follow Step 9.a and Step 9.b to prevent the
flywheel from rotating.
a. Install a suitable bolt (1) to flywheel (4).
b. Position a suitable piece of wood (3) between

bolt (1) and the floor.
10. Use the following method to tighten the flywheel
bolts to the correct torque.
a. Tighten bolts (2) hand tight, in the sequence

that is shown in Illustration 240 .
b. Tighten bolts (2) to a torque of 135 N·m
(100 lb ft) in the sequence that is shown in
Illustration 240 .
UENR4544 123
Illustration 240 .
11. Check the run out of the flywheel. Refer to
Specifications, “Flywheel” for further information.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.
b. Install the overspeed sensor. Refer to
Disassembly and Assembly, “Engine Speed
Sensor - (Overspeed Sensor) Remove and
c. Install the engine speed sensor. Refer to
Sensor - (Engine Speed for Governor Control)
i06510419
Crankshaft Rear Seal - Illustration 241 g01454205
Remove and Install 1. Use a 4 mm (1/8 inch) drill to make three equally
spaced holes in crankshaft rear seal (1).
Note: Ensure that debris does not enter the
Removal Procedure crankcase.
Table 35
2. Screw Tooling (A) firmly into one of the holes. Use
Required Tools Tooling (A) to dislodge crankshaft rear seal (1).
When the crankshaft rear seal begins to move,
unscrew Tooling (A). Install Tooling (A) in the next
A 27610311 Slide Hammer Puller 1 hole. Repeat the process using each hole, until the
crankshaft rear seal is removed.
Start By:
a. Remove the flywheel. Refer to Disassembly Table 36
and Assembly, “Flywheel - Remove” for the
correct procedure. Required Tools

NOTICE
Keep all parts clean from contaminants. B T6253/140 Rear Oil Seal Insertion Kit 1

component life. NOTICE
NOTICE Contaminants may cause rapid wear and shortened

Care must be taken to ensure that fluids are con- component life.
Be prepared to collect the fluid with suitable contain- Note: Do not lubricate the crankshaft rear seal or the
ers before opening any compartment or disassem- crankshaft. The crankshaft seal should be installed
bling any component containing fluids. dry.
Dispose of all fluids according to local regulations 1. Inspect the rear of the crankshaft for damage.
and mandates.
Ensure that the crankshaft is clean and dry.
124 UENR4544
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install” for the correct
procedure.
i06510425
Flywheel Housing - Remove

and Install
Removal Procedure
Table 37
Required Tools
Guide Studs
A - 2
M10 by 100 mm
Start By:
2. Ensure that Tooling (B) is clean, dry, and free from
damage. Install Tooling (B) (oil seal locator) to the a. Remove the engine speed sensor. Refer to
rear of the crankshaft. Disassembly and Assembly, “Engine Speed
Sensor - Remove and Install” for the correct
3. Position a new crankshaft rear seal (1) on Tooling procedure.
(B) (oil seal locator).
b. Remove the overspeed sensor. Refer to
Note: A new crankshaft rear seal is supplied with a Disassembly and Assembly, “Engine Speed
plastic sleeve. The plastic sleeve should be aligned Sensor (Overspeed) - Remove and Install” for
with the chamfer on Tooling (B) (oil seal locator).
c. Remove the starting motor. Refer to
4. Push crankshaft rear seal (1) squarely over Tooling Disassembly and Assembly, “Electric Starting
(B) (oil seal locator). The plastic sleeve will be Motor - Remove and Install” for the correct
forced out of the crankshaft rear seal. Discard the procedure.
plastic sleeve. Push the crankshaft rear seal up to
d. Remove the flywheel. Refer to Disassembly
the flywheel housing. and Assembly, “Flywheel - Remove” for the
5. Install Tooling (B) (outer sleeve). Lubricate the face correct procedure.
of the washer with clean engine oil and install the e. Remove the engine oil pan. Refer to
nut. Disassembly and Assembly, “Engine Oil Pan -
6. Tighten the nut on Tooling (B) until the crankshaft
rear seal is pushed into the bore in the flywheel
NOTICE
housing. Keep all parts clean from contaminants.
7. Remove Tooling (B). Contaminants may cause rapid wear and shortened
component life.
UENR4544 125
NOTICE
and mandates.
3. Use a suitable lifting device to support the weight

of flywheel housing (1). The flywheel housing
weighs approximately 150 kg (330 lb).
4. Remove bolts (4) from Positions (X). Install Tooling
(A) to Positions (X).
5. Remove remaining bolts (4).
6. Separate flywheel housing (1) from the crankcase.
7. Use the lifting device to remove the flywheel
1. Remove bolts (2) and bolts (3). housing.
2. Use a suitable hoist to lift the rear of the engine. 8. Use a suitable drift to remove the crankshaft rear
The weight of the engine is approximately 3350 kg seal from the flywheel housing.
(7385 lb). Raise the rear of the engine so that
there is a distance of 10 mm (0.4 inch) between
Table 38
flywheel housing (1) and the base frame.
Required Tools
Note: Ensure that the engine is supported.
Guide Studs
A - 2
M10 by 100 mm
B - Loctite 518 1
NOTICE
component life.
126 UENR4544
1. Ensure that the gasket surfaces of the flywheel

housing and the crankcase are clean and free
from damage. Ensure that the oil galleries in the
engine cylinder block are free from debris or
restrictions.
3. Install Tooling (A) to Positions (X) in the crankcase.

4. Use a suitable lifting device to lift flywheel housing
(1) into position. The flywheel housing weighs
Illustration 245 g01848256 approximately 150 kg (330 lb).
5. Align flywheel housing (1) with Tooling (A) and
2. Apply a fine bead of Tooling (B) to the rear of the
install the flywheel housing to the crankcase.
crankcase. Refer to Illustration 245 for the correct
pattern of application. Ensure that camshaft Bore Note: Ensure that the flywheel housing is seated on
(Y) and oil Holes (Z) are not contaminated with the dowels in the crankcase.
Tooling (B).
6. Install bolts (4) hand tight. Remove Tooling (A).
Note: The flywheel housing should be installed within Install the remaining bolts.
10 minutes of applying Tooling (C).
7. Ensure that the bottom face of the flywheel
Application of Tooling (C) to the rear of the housing is aligned with the bottom face of the
crankcase crankcase. The bottom face of the flywheel
housing should be aligned with the bottom face of
the crankcase within 0.10 mm (0.004 inch).
UENR4544 127
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the
correct procedure.
b. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install” for the correct
procedure.
c. Install the starting motor. Refer to Disassembly
and Assembly, “Electric Starting Motor -
d. Install the overspeed sensor. Refer to
Sensor (Overspeed) - Remove and Install” for
e. Install the engine speed sensor. Refer to
Sensor - Remove and Install” for the correct
procedure.
i06513739
9. Use a suitable hoist to lower the rear of the engine Vibration Damper and Pulley -
onto the base frame. The weight of the engine is
approximately 3350 kg (7385 lb). Remove and Install
10. Install bolts (2) and bolts (3). Tighten the bolts (Twin Vibration Dampers)
securely.
11. Install a new crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear Removal Procedure
Seal - Remove and Install” for the correct Table 39
procedure.
Required Tools
Support Studs Flywheel and

A T6253/157 2
Damper
B T6253/214 Damper Lifting Tool 1
C T6253/209A Retaining Plate 1
Crankshaft Adapter
D T6253/209 1
Extractor
Start By:
a. Remove the V-belts from the fan drive. Refer to
Disassembly and Assembly, “V-Belts - Remove
b. Remove the mounting bracket for the governor
actuator. Refer to Disassembly and Assembly,
“Governor Actuator - Remove and Install” for
NOTICE
component life.
128 UENR4544
1. Make a temporary mark to show the position of the

pulley on the shaft.
5. Remove two bolts (4) from Positions (X). Install

Tooling (A) to Positions (X).
2. Remove Allen head bolts (2) from pulley (1). 6. Remove the remaining bolts (4). If necessary, tap
the shaft with a soft faced hammer to separate the
shaft from front damper (5). Remove the shaft.

Using the jacking holes to release the pulley from the
shaft Illustration 251 g01581897
3. Lubricate two Allen head bolts (2) with clean 7. Install Tooling (B) and a suitable lifting device to
engine oil. Install the Allen head bolts into the support the weight of front damper (5). The weight
jacking holes in pulley (1). Tighten the Allen head of the damper is approximately 95 kg (210 lb).
bolts alternately until the center of the pulley is
8. Use Tooling (B) to remove front damper (5).
released from shaft (3).
4. Remove pulley (2) from shaft (3). If necessary,
remove the key from the shaft.
UENR4544 129
14. Remove Tooling (D) and remove Tooling (C).

15. Use Tooling (B) to remove the assembly of rear
damper (8) and adapter (9). Lay the assembly of
the rear damper and the adapter on a flat surface
with the adapter downward.
10. Remove bolts (6) and retaining plate (7).

11. Install Tooling (B) and a suitable lifting device to
support the weight of rear damper (8). The weight
of the rear damper and the adapter is
16. Remove bolts (10) and separate rear damper (8)
from adapter (9).
Table 40
Required Tools
Support Studs for Flywheel

A T6253/157 2
and Damper
B T6253/214 Damper Lifting Tool 1
Loctite C5-A
E - 1
Anti-Seize Compound
12. Install Tooling (C) to the nose of the crankshaft. NOTICE

component life.
1. Ensure that the nose of the crankshaft and the
Make sure to wear all necessary protective bore of the adapter are clean, dry, and free from
equipment. damage. Ensure that the casings of the dampers
Follow the recommended procedure and use all are free from damage.
Note: If new dampers are installed, the casings
should be painted to prevent corrosion.
13. Install Tooling (D) to adapter (9). Lubricate the
threads of the forcing bolt with clean engine oil.
Tighten the forcing bolt to pull the assembly of
adapter (8) and rear damper (9) off the crankshaft.
Note: The adapter will be released from the
crankshaft with considerable force.
130 UENR4544
6. Use the lifting device to position the assembly of

adapter (9) and rear damper (8) onto the
crankshaft.
2. Position adapter (9) on rear damper (8) and install

bolts (10).
7. Install plate (7) and bolt (6).

8. Remove Tooling (B) and install remaining bolts (6).
Repeat Step 9 until a torque of 340 N·m (250 lb ft)
has been achieved.
Note: Continue to tighten the bolts until the bolts
stop turning.

The tightening sequence for the damper bolts
3. Use the following method to tighten the rear

damper bolts to the correct torque.

Illustration 256 .
Illustration 256 .
4. Inspect the crankshaft front seal for leaks. If there
are any oil leaks, replace the crankshaft front seal.
Refer to Disassembly and Assembly, “Crankshaft
Front Seal - Remove and Install” for the correct
procedure.
5. Install Tooling (B) and a suitable lifting device to
rear damper (8). The weight of the damper and the
adapter is approximately 120 kg (265 lb).
UENR4544 131

Illustration 256 .
17. The mating surface of the two halves of pulley (1)

must clean, dry, and free from damage. Align the
halves of the pulley. Lubricate the threads of Allen
head bolts (2) with Tooling (E). Install the Allen
head bolts to the pulley finger tight. If necessary,
install the key to the keyway on shaft (3).
18. Install pulley (1) to shaft (3). Align pulley (1) with
the pulley on the fan drive.
19. Tighten Allen head bolts (2). Tighten the Allen
head bolts alternately and tighten the Allen head
bolts evenly to a torque of 115 N·m (85 lb ft).
10. Install Tooling (A) to the adapter. 20. Tap the outer half of pulley (1) with a soft faced
11. Install Tooling (B) and a suitable lifting device to hammer to seat the two halves of the pulley.
front damper (5). The weight of the damper is 21. Again, tighten Allen head bolts (2) to a torque of
approximately 95 kg (210 lb). 115 N·m (85 lb ft). Check the alignment of pulley
12. Use the lifting device to position damper (5) onto (1) with the pulley on the fan drive. Ensure that the
Tooling (A). Slide the damper into position against pulleys are aligned.
the adapter. Note: After the engine has been run for the
13. Position shaft (3) onto Tooling (A). Slide the shaft appropriate length of time, check the tightness of the
into position against damper (5). Allen head bolts that secure the pulley.
14. Install bolts (4) hand tight.

15. Remove Tooling (A) and install the remaining
bolts (4).
16. Use the following method to tighten the front
damper bolts to the correct torque.

Illustration 256 .
132 UENR4544
End By:
a. Install the governor actuator and the mounting
bracket. Refer to Disassembly and Assembly,
“Governor Actuator - Remove and Install” for
b. Install the V-belts to the fan drive. Refer to
Disassembly and Assembly, “V-Belts - Remove
i06510432
Crankshaft Front Seal -

Remove and Install
Removal Procedure
Table 41
Required Tools
A 27610311 Slide Hammer Puller 1 1. Use a 4 mm (1/8 inch) drill to make three equally
spaced holes in crankshaft front seal (1).
Start By: Note: Ensure that debris does not enter the
crankcase.
a. Remove the damper from the crankshaft. Refer
to Disassembly and Assembly, “Vibration
2. Screw Tooling (A) firmly into one of the holes. Use
Damper and Pulley - Remove and Install” for
the correct procedure. Tooling (A) to dislodge crankshaft front seal (1).
When the crankshaft front seal begins to move,
NOTICE unscrew Tooling (A). Install Tooling (A) in the next
Keep all parts clean from contaminants. hole. Repeat the process using each hole, until the
crankshaft front seal is removed.
component life.
Table 42
NOTICE Required Tools
tained during performance of inspection, mainte- Tool Part Number Part Description Qty
Be prepared to collect the fluid with suitable contain- B T6253/141 Front Oil Seal Insertion Kit 1
NOTICE
Dispose of all fluids according to local regulations Keep all parts clean from contaminants.
and mandates.
component life.
Note: Do not lubricate the crankshaft front seal or the

crankshaft. The crankshaft front seal should be
installed dry.
1. Inspect the nose of the crankshaft for damage.

Ensure that the crankshaft is clean and dry.
UENR4544 133
End By:
a. Install the damper to the crankshaft. Refer to
Disassembly and Assembly, “Vibration
i06510434
Gear Group (Front) - Remove
Removal Procedure
Start By:
a. Remove the rocker assemblies. Refer to
b. Remove the timing case. Refer to Disassembly
and Assembly, “Housing (Front) - Remove” for
Illustration 262 g01861574 the correct procedure.
2. Ensure that Tooling (B) is clean, dry, and free from NOTICE
damage. Install Tooling (B) (oil seal locator) to the Keep all parts clean from contaminants.
nose of the crankshaft.
3. Position a new crankshaft front seal (1) on Tooling component life.
(B) (oil seal locator).
Note: A new crankshaft front seal is supplied with a NOTICE
plastic sleeve. The plastic sleeve should be seated Care must be taken to ensure that fluids are con-
over the chamfer on Tooling (B) (oil seal locator). tained during performance of inspection, mainte-
4. Push crankshaft front seal (1) squarely over Be prepared to collect the fluid with suitable contain-
Tooling (B) (oil seal locator). The plastic sleeve will bling any component containing fluids.
be forced out of the crankshaft front seal. Push the
crankshaft front seal up to the timing case. Discard Dispose of all fluids according to local regulations
the plastic sleeve. and mandates.
5. Install Tooling (B) (outer sleeve). Lubricate the face

of the washer with clean engine oil and install the
nut.
6. Tighten the nut on Tooling (B) until the crankshaft
front seal is pushed into the bore in the timing
case.
7. Remove Tooling (B).
134 UENR4544

Alignment of the timing marks
5. Remove bolts (6) and remove plate (5).
1. Align the timing marks on the gears. Refer to
6. Remove idler gear (4).
Illustration 263 .
7. If necessary, remove Allen head bolts (8) and
remove hub (7) from the backplate.
i06510437
Gear Group (Front) - Install
Table 43
Required Tools
21825617 Dial Indicator Group 1

A
NOTICE
component life.
2. Remove bolts (2).
3. Carefully remove camshaft gear (1) from the
camshaft.
4. Do not remove dowel (3) from the camshaft unless
the dowel is damaged.
UENR4544 135
4. Lubricate the hub with clean engine oil. Position

idler gear (4) on the hub.
Note: Ensure that the idler gear is correctly meshed
with the crankshaft gear and with the oil pump gear.
5. Lubricate plate (5) with clean engine oil. Position

the plate and install bolts (6). Tighten the bolts to a
1. Inspect hub (7) for wear or damage. Check the

outside diameter of the hubs. Refer to
Specifications, “Gear Group (Front)” for more
information.
2. Position hub (7) on the backplate. Position the oil
hole in the hub in Position (A). Refer to Illustration
266 . Install Allen head bolts (7). Tighten the Allen Illustration 268 g01856993
head bolts to a torque of 47 N·m (35 lb ft).
Checking the end play and the backlash of an idler
gear
6. Use feeler gauges to check the end play of the

idler gears. Use Tooling (A) to check the backlash
between the idler gears and the crankshaft gear.
Refer to Specifications, “Gear Group (Front)” for
more information.
3. Inspect idler gears (4) for wear or damage. Check

the inside diameter of the bushes. Refer to
Specifications, “Gear Group (Front)” for more
information.
136 UENR4544

Alignment of the timing marks Checking end play of the camshaft
9. Use Tooling (A) to check the end play of the

camshaft. Use Tooling (A) to check the backlash
between the camshaft gear and the crankshaft
gear. Refer to Specifications, “Gear Group (Front)”
for more information.
10. Lubricate all gears with clean engine oil.
7. Align the timing marks on gears (1) with the timing

marks on the crankshaft gear. Refer to Illustration
269 . Align the hole in the camshaft gear with
dowel (3) in the nose of the camshaft. Position the
camshaft gear on the camshaft.
150 N·m (110 lb ft).
UENR4544 137
End By: Note: Removal of the timing case without removing

the engine oil pan is possible. The bolts that secure
a. Install the timing case. Refer to Disassembly the engine oil pan to the timing case should be
and Assembly, “Housing (Front) - Install” for removed so that the engine oil pan can be lowered.
the correct procedure. The gasket should then be separated from the timing
b. Install the rocker assemblies. Refer to case.
i06510440
Housing (Front) - Remove

(Timing Case)
Removal Procedure
Start By:
a. Remove the water pumps. Refer to
Disassembly and Assembly, “Water Pump -
b. Remove the damper from the crankshaft. Refer
to Disassembly and Assembly, “Vibration
c. Remove the crankshaft front seal . Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove and Install” for the correct
procedure.
NOTICE
component life. 3. Remove stop solenoid (2) and stop lever (1). Refer
to Disassembly and Assembly, Governor Actuator
- Remove and Install for the correct procedure.
NOTICE
Care must be taken to ensure that fluids are con- 4. Attach a suitable lifting device to support the
weight of timing case (4). The timing case weighs
Be prepared to collect the fluid with suitable contain- approximately 90 kg (200 lb).
ers before opening any compartment or disassem- 5. Remove bolts (3) and nuts and bolts (7) from
timing case (4). Note the position of the bolts and
Dispose of all fluids according to local regulations the nuts and bolts for installation purpose.
and mandates.
6. Use suitable lifting device to remove timing case
(4) from back plate (6). Care should be take not to
1. Remove tube assembly from the water damage the nose of the crankshaft as the timing
temperature regulator and the elbow on the water case is removed.
pump. Refer to Disassembly and Assembly,
“Water Temperature Regulator - Remove and 7. Remove gasket (5) (not shown).
2. If necessary, remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
138 UENR4544
8. If necessary, follow Step 8.a through Step 8.c to 9. If necessary, follow Step 9 through Step 9.b to
remove adapter (9) from timing cover (4). remove oil seal (12) and bush (13) from timing
cover (4).
a. Remove nuts and washers (8) from adapter
(9). Remove the adapter from timing cover (4). a. Use a suitable tool and remove oil seal (12)
from timing cover (4). Ensure that the timing
b. Remove gasket (10). cover is not damaged as the oil seal is
removed.
c. If necessary, remove stud (11) from timing
cover (4). b. If necessary, place timing cover (4) on a
suitable press. Use a suitable tool to press out
bush (13) from the timing cover.
i06510443
Housing (Front) - Install

(Timing Case)
Table 44
Required Tools
(continued)
UENR4544 139
(Table 44, contd)

Tool Part Number Part Description Qty b. Position a new gasket (10) onto timing case
(4).
Guide Studs
A - 2
M10 by 100 mm c. Install adapter (9) to timing case (4).
B T6253/354 Seal Carrier Alignment Tool 1
d. Install nuts and washers (8) to adapter (9).
C -
1 Tighten nuts finger tight.
Nut lock
NOTICE
component life.
1. Ensure that the gasket surface of the timing case

and the back plate are clean.
2. Ensure that all components for the timing case are
free from wear or damage. Replace any

install bush (13) and oil seal (12) to timing cover
(4).
a. If necessary, place timing cover (4) on a

suitable press. Use a suitable tool to install
bush (13) to the timing cover. Ensure that the
bush is installed to the correct depth.
b. Use a suitable tool and install oil seal (12) to

timing cover (4). Lubricate the oil seal with
clean engine oil.
3. If necessary, follow Step 3 through Step 3.d to

install adapter (9) to timing case (4).
a. If necessary, install studs (11) to timing case

(4). Apply Tooling (C) to the threads of studs
(11). Install the studs to the timing case and
tighten the studs securely.
140 UENR4544
7. Align gasket (5) (not shown) with Tooling (A).

Install the gasket to back plate (6).
8. Attach a suitable lifting device to timing case (4).
The timing case weighs approximately 90 kg
(200 lb).
9. Use the suitable lifting device to install timing case
(4) to back plate (6). Care should be take not to
damage the nose of the crankshaft or the oil
seal for the stop control shaft as the timing
case is installed.
10. Install bolts (3) and nuts and bolts (7) to timing
case (4). Hand tighten the bolts and the nuts and
bolts.
Note: Ensure that bolts of different lengths are
installed in the correct positions. Ensure that gasket
(5) (not shown) protrudes below the base of the
timing case.
Illustration 277 g06019124 11. Remove Tooling (A) and install remaining bolts
(3).
12. Remove suitable lifting device from timing case
(4).
Tighten the nuts and bolts (7) to a torque of
47 N·m (35 lb ft).
Remove excess material from gasket (5) (not
shown). The gasket should be flush with the base
of the timing case.
14. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the
correct procedure.
15. Install stop lever (1) and stop solenoid (2). Refer
to Disassembly and Assembly, Governor Actuator
- Remove and Install for the correct procedure.
5. Ensure that dowel (14) and dowel (15) are

correctly located in the engine cylinder block and
back plate (6).
6. Install Tooling (A) into Positions (X) on back plate
(6).
UENR4544 141
End By:
a. Install the damper to the crankshaft. Refer to
Disassembly and Assembly, “Vibration
b. Install the water pumps. Refer to Disassembly
and Assembly, “Water Pump - Install” for the
correct procedure.
i06510445
Crankcase Breather - Remove

and Install
Removal Procedure
NOTICE
16. If necessary, Install Tooling (B) to timing case (4) component life.
to align adapter (9) to the timing case. Tighten nuts
and washers (8) to a torque of 25 N·m (18 lb ft).
NOTICE
17. Install a new crankshaft front oil seal. Refer to Care must be taken to ensure that fluids are con-
Disassembly and Assembly, “Crankshaft Front Oil tained during performance of inspection, mainte-
Seal - Remove and Install” for the correct nance, testing, adjusting and repair of the product.
procedure. Be prepared to collect the fluid with suitable contain-
18. If necessary, install tube assembly from the water bling any component containing fluids.
temperature regulator and the elbow on the water
pump. Refer to Disassembly and Assemble, and mandates.
“Water Temperature Regulator - Remove and
142 UENR4544
1. Disconnect the Original Equipment Manufacture 4. If necessary, follow Step through Step to
(OEM) hose assembly from the crankcase disassemble crankcase breather (2).
breather (2). Refer to the OEM for the correct
procedure. a. Make temporary marks on crankcase breather
(2) and cover (8) for installation purposes.
2. Loosen hose clamp (4) and hose clamp (6).
Remove hose assembly (5) from crankcase b. Place crankcase breather (2) in a suitable
breather (2) and the timing cover. support.
3. Support crankcase breather (2) and remove bolts c. Remove bolts (7) from the assembly of
(3). Remove the crankcase breather from the crankcase breather (2).
water rail.
d. Remove cover (8) from the assembly of
crankcase breather (2)
e. Remove O-ring (9) from the assembly of

crankcase breather (2).
f. Remove baffle (10) from the assembly of

crankcase body (11).
NOTICE
component life.
1. Ensure that all components of the crankcase

breather are free from wear or damage. Replace
UENR4544 143
breather body and notch (12) in the baffle are

correctly aligned.
e. Install a new O-ring (9) to the assembly of

f. Install cover (8) to the assembly of crankcase

breather (2). Ensure that the cover is correctly
aligned with temporary marks.
g. Install bolts (7) to the assembly of crankcase

breather (2). Tighten the bolts to a torque of
50 N·m (37 lb ft).
3. Position crankcase breather (2) onto the water rail.

Support crankcase breather (2) and install bolts
(3). Tighten the bolts to a torque of 50 N·m
(37 lb ft).
4. Install hose assembly (5) to crankcase breather (2)
and the timing cover. Ensure that hose clamp (4)
and hose clamp (6) are correctly orientated.
5. Tighten hose clamp (4) and hose clamp (6) to a
2. If necessary, follow Step through Step to assemble torque of 8 N·m (71 lb in).
a. Clean all components of the assembly of

b. Inspect pin (13)for damage. Replace the pin if

the pin is damaged.
c. Place crankcase breather (2) in a suitable

support.
d. Install baffle (10) to crankcase breather body

(11). Ensure that pin (13)in the crankcase
144 UENR4544
6. Connect the Original Equipment Manufacture Note: If necessary, carefully tap the rocker box cover
(OEM) hose assembly to the crankcase breather with a soft faced hammer to loosen the rocker box
(2). Refer to the OEM for the correct procedure. cover.
3. Remove gasket (4) (not shown) from rocker box

i06510448
cover (1).
Valve Mechanism Cover - Installation Procedure
Remove and Install
NOTICE
(Rocker Box Cover) Keep all parts clean from contaminants.
component life.
Removal Procedure
1. Ensure that the rocker box cover is clean and dry.
NOTICE Ensure that the gasket surface of the rocker box
cover and rocker box cover are clean and free
Contaminants may cause rapid wear and shortened from damage.
component life.
NOTICE
and mandates.
2. Remove the protective backing from gasket (4)

(not shown) and install the gasket to rocker box
cover (1). Ensure that the gasket is correctly
positioned onto the rocker box cover.
3. Position rocker box cover (1) on the rocker box.
Install Allen head bolts (2) and washers (3).
1. Remove screw head fastener (2) and washers (3).

2. Remove rocker box cover (1) from the rocker box.
UENR4544 145
4. Tighten screw head fastener (2) evenly to a torque

of 4 N·m (35 lb in).
i06510450
Valve Mechanism Cover Base -

Remove and Install
(Rocker Box)
Removal Procedure
Start By:
NOTICE
component life. 2. Loosen tube assembly (3) at both ends. Allow the
oil to drain from the oil rail.
NOTICE 3. Remove bolt (4). Remove tube assembly (3).

tained during performance of inspection, mainte- Note: Cap the tube assembly and the connections.
Be prepared to collect the fluid with suitable contain- 4. Loosen tube assembly (2) at both ends. Allow the
ers before opening any compartment or disassem- fuel to drain from the fuel rail. Remove the tube
bling any component containing fluids. assembly.
Dispose of all fluids according to local regulations Note: Cap the tube assembly and the connections.
and mandates.
5. Remove Allen head bolts (5) and washers (6).

6. Remove rocker box (1).
Note: If necessary, carefully tap the rocker box with a
soft faced hammer to loosen the rocker box.
146 UENR4544
8. Remove O-ring seal (8). 2. If necessary, follow Step 2.a through Step 2.c to
install stud (9) and stud (10) to cylinder head (11).
remove stud (9) and stud (10) from cylinder head a. Ensure the threads of stud (8) and stud (10)
(11). are clean and dry. Ensure the holes for the
stud in cylinder head (11) are clean and dry.
a. To remove stud (9) and stud (10) from cylinder
head (11) first drain the coolant to a level that b. Apply Tooling (A) to the threads of stud (8) and
is below the cylinder head. Refer to Operation stud (10).
and Maintenance Manual, “Cooling System
Coolant - Change” for the correct procedure. Note: Apply the Tooling to the end of the studs that
have the short thread.
b. Use a suitable stud extractor to stud (9) and
stud (10) from cylinder head (11). c. Install stud (8) and stud (10) to cylinder head
(11). Tighten the studs to a torque of 47 N·m
Installation Procedure (35 lb ft).
Table 45
Note: Ensure that the coolant is filled to the correct
Required Tools level. Refer to Operation and Maintenance Manual,
Tool Part Number Part Description Qty “Cooling System Coolant - Change” for the correct
procedure.
A - Loctite 2701 1
3. Position a new O-ring seal (7) in the recess in
cylinder head (11).
NOTICE
component life.
1. Ensure that the rocker box is clean and free from

damage. Ensure that the gasket surface of the
cylinder head is clean, and free from damage.
UENR4544 147
9. Remove the plugs and caps. Connect tube

assembly (2) to rocker box (1). Tighten the nuts at
both ends to a torque of 20 N·m (177 lb in). Use a
suitable tool to hold the connections on the rocker
box and the rail as the tube nuts are tightened.
Operation and Maintenance Manual, Fuel System
- Prime for the correct procedure.
End By:
a. Install the rocker assembly. Refer to
Illustration 291 g06013360 Shaft - Install” for the correct procedure.
4. Position a new gasket (7) (not shown) onto the i06510454

cylinder head.
5. Align rocker box (1) with the dowels in the cylinder
Rocker Arm and Shaft -
head and install the rocker box. Remove
6. Install Allen head bolts (5) and washers (6).
Tighten the Allen head bolts to a torque of 70 N·m
(50 lb ft). Removal Procedure
Start By:
a. Remove the cover from the rocker box. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
correct procedure.
NOTICE
component life.
Note: Make temporary identification marks on the

rocker assembly, on the bridge pieces and on the
pushrods to show the location.
7. Remove the plugs and caps. Connect tube

assembly (3) to rocker box (1). Tighten the nuts at
both ends to a torque of 20 N·m (177 lb in). Use a
suitable tool to hold the connections on the rocker
box and the rail as the tube nuts are tightened.
8. Install bolt (4) to the clip. Tighten the bolt to a
148 UENR4544

remaining rocker assemblies.
i06510457
Rocker Arm - Disassemble
Start By:
NOTICE
component life.
Rocker Arm and Shaft Assembly

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

original location and orientation. Do not interchange
used components.
1. Remove nut (1) and nut (3).

2. Carefully remove rocker assembly (2) from the
rocker box. Take care not to misplace pad (5).
3. Remove pad (5) from the fuel injector.
4. Remove bridge piece (4) and bridge piece (6) from
the rocker box.
5. Remove pushrod (7) (not shown), pushrod (8) and
pushrod (9). 2. Remove rocker arm assembly (3) from rocker shaft
(4),
UENR4544 149
3. Remove rocker arm assembly (2) from rocker shaft 7. Inspect pad (7) for wear or damage. If the pad is
(4). worn or damaged, use a suitable press to remove
the pad from bridge piece (7).
4. Remove rocker arm assembly (1) from rocker shaft
(4).
i06510460
Rocker Arm - Assemble
Assembly Procedure
Table 46
Required Tools
A - Loctite 7471 Activator 1

B - Loctite 603 1

NOTICE
5. If necessary, remove nuts (5) and adjusters (6)
from the rocker arms. Contaminants may cause rapid wear and shortened
component life.
1. Check the bridge piece for wear or damage. Check

the clearance between the bridge piece and the
guide pillar in the cylinder head. Check that the nut
and the adjuster are free from damage.
Note: The components must be installed in the
used components.
6. If necessary, remove nut (8) and adjuster (9) from

bridge piece (10).
150 UENR4544
4. Check the rocker arms for wear or damage. Check

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

used components.
5. If necessary, install adjusters (6) to the rocker arms

and install nuts (5) to the adjuster.
2. If pad (7) on bridge piece (10) required

replacement. Follow Step 2.a through Step 2.e to
install a new pad.
a. Ensure the new pad (7) is clean and dry.
b. Ensure the bore in bridge piece (10) is clean

and dry.
c. Apply Tooling (A) to Stem (X) on the pad and

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

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

is not contaminated with Tooling (B).
e. Use a suitable press to install pad (7) to bridge Illustration 301 g03670959
piece (10).
6. Lubricate the rocker shaft and the rocker arm
Note: Position the bridge piece with the pad
assemblies with clean engine oil.
upward. Allow Tooling (B) to cure for 2 hours
before installing the bridge piece. 7. Install rocker arm assembly (1), rocker arm
assembly (4)
3. Install adjuster (17) to bridge piece (6) and install
nut (18) to the adjuster. 8. Install rocker arm assembly (2) to rocker shaft (4).
UENR4544 151
9. Install rocker arm assembly (3) to rocker shaft (4).

End By:
a. Install the rocker assembly. Refer to
i06510461
Rocker Arm and Shaft - Install
Table 47
Required Tools
C 21825607 Angle Gauge 1

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

from wear or damage. Replace any components
that are worn or damaged.
2. Apply clean engine oil to both ends of the

pushrods. Install pushrod (7) (not shown), pushrod
(8) and pushrod (9) to the engine with the cup
upward. Ensure that the ball end of each pushrod
is correctly seated in the cam follower.
3. Lubricate the posts for the bridge pieces and
lubricate the valves with clean engine oil.
4. Install bridge piece (4) and bridge piece (6).
5. Equalize the bridge pieces. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve
Lash - Adjust” for the correct procedure.
152 UENR4544
6. Lubricate pad (5) with petroleum jelly and install Start By:
the pad to rocker assembly (2).
a. Remove the fuel rail. Refer to Disassembly and
7. Position rocker assembly (2) onto the rocker box. Assembly, “Fuel Manifold (Rail) - Remove and
Take care not to misplace pad (5). Install” for the correct procedure.
Note: Ensure that the rocker assembly is aligned b. Remove the appropriate sections of the
with the dowels in the rocker box. Ensure that the exhaust manifold. Refer to Disassembly and
adjustment screws are properly seated in the ends of Assembly, “Exhaust Manifold - Remove and
the pushrods. Install” for the correct procedure.
c. Remove the appropriate sections of the inlet
8. Install nut (1) and nut (3). Evenly tighten the nuts to manifold. Refer to Disassembly and Assembly,
pull the rocker assembly into position. Tighten the “Inlet Manifold - Remove” for the correct
nuts to a torque of 120 N·m (90 lb ft). procedure.
9. Use Tooling (C) to turn nut (1) and nut (3) through NOTICE
an additional 90 degrees. Cylinder heads that are being removed for over-
haul on 4008-30 have a valve seat and valve angle
10. Adjust the engine valve lash. Refer to Systems of 20 degree. For further information contact your
Operation, Testing and Adjusting, “Engine Valve Perkins distributor.
Lash - Adjust” for the correct procedure. Adjust the
fuel injector timing. Refer to Systems Operation,
Testing and Adjusting, “Fuel Injector Adjustment” NOTICE
for the correct procedure. Keep all parts clean from contaminants.
End By: Contaminants may cause rapid wear and shortened
component life.
a. Install the cover to the rocker box. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
correct procedure. NOTICE
i06511729 nance, testing, adjusting and repair of the product.
Cylinder Head - Remove ers before opening any compartment or disassem-
and mandates.
Removal Procedure
Table 48
Required Tools suitable container. Refer to Operation and
Tool Part Number Part Description Qty Maintenance Manual, “Cooling System Coolant -
Change” for the correct procedure.
T6253/237 Cylinder head Lifting Tool 1
A
- Bolts (M10 by 25 mm) 2
UENR4544 153
e. Remove O-ring seal (3). Remove gaskets (5).

4. Remove the appropriate fuel injector. Refer to
Disassembly and Assembly, “Fuel Injector -
5. Remove the appropriate rocker box. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove and Install” for the correct
procedure.
6. Remove the fuel injection control linkage from the
cylinder head. Refer to Disassembly and
Assembly, “Valve Mechanism Cover Base -

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

of the bolts should be marked with a dot from a
center punch. Any bolts that have two dots before
removal should not be reused.
Front section of the coolant rail
2. To remove the front cylinder heads, the water

temperature regulator housing (8) and crankcase
breather (9) will need to be removed. Refer to
Disassembly and Assembly, “Temperature
Regulator Housing (Thermostat Housing) -
Remove and Install” and Disassembly and
Assembly, “Crankcase Breather - Remove and
Install” for the correct procedures.
3. Follow Step 3.a through Step 3.e to remove the
appropriate sections of the coolant rail.
a. Remove bolts (7) from heat shield (6).

Remove the heat shield from assembly of
coolant rail (4).
b. Remove nuts and bolts (2) from coolant rail

(4).
c. Remove bolts (1) from coolant rail (4).
d. Remove coolant rail (4) from the cylinder

head.
154 UENR4544
10. Attach Tooling (A) to cylinder head (12). Carefully

lift the cylinder head off the cylinder block. The
weight of the cylinder head is approximately 40 kg
(88 lb).

The cylinder head tightening sequence
8. Gradually loosen cylinder head bolts (10) in

reverse numerical order to the sequence that is
shown in Illustration 307 .
9. Remove cylinder head bolts (10) and spacers (11)
from cylinder head (12).
11. Remove O-ring seal (14) from recess (13) of

cylinder head (12).
UENR4544 155
12. Remove O-ring seal (15), O-ring seal (16), O-ring 2. Install flame ring (17).
seal (18), O-ring seal (19) and O-ring seal (20).
3. Install new O-ring seals (15), (16), (18), (19) and
13. Remove flame ring (17). (20).
i06511730
Note: Use petroleum jelly to hold the O-ring seals in
position.
Cylinder Head - Install
Table 49
Required Tools
T6253/237 Cylinder head Lifting Tool 1

A
- Bolts (M10 by 25 mm) 2
Loctite C5-A Anti-Seize

B - 1
Compound
NOTICE
component life.
1. Thoroughly clean the gasket surfaces of the
cylinder head and the crankcase. Ensure that 4. Install a new O-ring seal (14) to recess (13) of
there is no debris in the cylinder bores, the coolant cylinder head (12). Ensure that the O-ring seal is
passages, or the lubricant passages. correctly located into the recess of the cylinder
head.
Note: Use petroleum jelly to hold the O-ring seal in

position.
156 UENR4544
5. Attach Tooling (A) to cylinder head (12). Carefully,

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

control linkage when the cylinder head is lowered into
position. Ensure that the cylinder head is aligned with
the dowels in the crankcase. Ensure that the retainer
and the O-ring seal are not dislodged.

Marking of the cylinder head bolts
(X) After the first removal, reuse the cylinder head bolt.
(Y) After the second removal, reuse the cylinder head bolt.
(Z) After the third removal, renew the cylinder head bolt.
6. Inspect the cylinder head bolts for previous use.

Refer to Illustration 314 . If necessary, replace the
cylinder head bolts.

The cylinder head tightening sequence
UENR4544 157
7. Apply Tooling (B) to threads in Position (X) of

cylinder head bolts (10). Apply Tooling (B) to the
faces of washers (11).
8. Install cylinder head bolts (10) and spacers (11) to
cylinder head (12).
9. Tighten cylinder head bolts (10) according to the
following procedure:
a. Tighten the cylinder head bolts hand tight in

the sequence that is shown in Illustration 317 .
b. Tighten the cylinder head bolts to a torque of

175 N·m (130 lb ft) in the sequence that is
c. Use Tighten the cylinder head bolts through a
further 120 degrees. Turn the cylinder head
bolts in the sequence that is shown in
Illustration 317 .
Note: Sometimes, it may not be possible to follow the

procedure that is described in Step 9. If necessary,
follow the alternative procedure that is described in
Step 10 to tighten the cylinder head bolts.
10. The alternative procedure for tightening cylinder

head bolts (6)
a. Tighten the cylinder head bolts hand tight in

the sequence that is shown in Illustration 317 .
b. Tighten the cylinder head bolts to a torque of

shown in Illustration 317 . Illustration 318 g06005878
c. Tighten the cylinder head bolts to a torque of Front section of the coolant rail
14. Follow Step 14.a through Step 14.e to install the
sections of the coolant rail to the cylinder head.
d. Tighten the cylinder head bolts to a torque of
540 N·m (400 lb ft) in the sequence that is a. Install O-ring seal (3) to coolant rail (4). Install
shown in Illustration 317 . gasket (5) to the cylinder head.
e. Tighten the cylinder head bolts to a torque of b. Install coolant rail (4) to the cylinder head.
shown in Illustration 317 . c. Install bolts (1) finger tight. Install nuts and
bolts (2) finger tight.
11. Install the fuel injection control linkage to the
cylinder head. Refer to Disassembly and d. Tighten bolts (1) to a torque of 50 N·m
Assembly, “Valve Mechanism Cover Base - (35 lb ft). Tighten nuts and bolts (2) to a torque
Remove and Install” for the correct procedures. of 50 N·m (35 lb ft).
12. Install the rocker box to the cylinder head. Refer e. Position heat shield (6) to assembly of coolant
to Disassembly and Assembly, “Valve Mechanism rail (4). Install bolts (7) to the heat shield .
Cover Base - Remove and Install” for the correct Tighten the bolts to a torque of 25 N m
procedures. (221 lb in).
13. Install the fuel injector to the cylinder head. Refer
to Disassembly and Assembly, “Fuel Injector -
158 UENR4544
15. To install the front cylinder heads, the water

temperature regulator housing (8) and crankcase
breather (9) will need to be installed. Refer to
Disassembly and Assembly, “Temperature
Regulator Housing (Thermostat Housing) -
Remove and Install” and Disassembly and
Assembly, “Crankcase Breather - Remove and
16. Fill the cooling system with coolant to the correct
level Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the correct
procedure.
End By:
a. Install the appropriate sections of the inlet
manifold. Refer to Disassembly and Assembly,
“Inlet Manifold - Install” for the correct
procedures.
b. Install the appropriate sections of the exhaust
manifold. Refer to Disassembly and Assembly,
“Exhaust Manifold - Remove and Install” for
the correct procedures.
1. Remove bolts (2) from the assembly of cam
c. Install the fuel rail. Refer to Disassembly and follower (1).
Assembly, “Fuel Manifold (Rail) - Remove and
Install” for the correct procedures. 2. Remove the assembly of cam follower (1) from the
crankcase. The weight of the cam follower is
i06511731 approximately 16 kg (35 lb).
Lifter Group - Remove 3. Remove gasket (3) (not shown).

4. If necessary, remove the dowels.Do not remove
(Cam Followers) dowels from the crankcase unless the dowels
are damaged.
Removal Procedure i06511734
NOTICE
Lifter Group - Disassemble
Keep all parts clean from contaminants. (Cam Followers)
component life.
NOTICE Start By:
nance, testing, adjusting and repair of the product. a. Remove the assembly of the cam followers.
Be prepared to collect the fluid with suitable contain- Refer to Disassembly and Assembly, “Lifter
ers before opening any compartment or disassem- Group - Remove (Cam Followers)” for the
bling any component containing fluids. correct procedure.
Dispose of all fluids according to local regulations NOTICE

and mandates. Keep all parts clean from contaminants.
component life.
UENR4544 159

1. Make temporary marks on jet (1) for installation
purposes.
2. Remove Allen head bolt (2).and remove jet (1).
3. Make a temporary mark on shaft (6) for installation
purposes.
4. Remove Allen head bolt (3) (not shown) Allen head
bolt (4) from cam follower body (5).
5. Remove shaft (6) from cam follower body (5).
Support the weight of the cam followers as the
shaft is removed.
6. Make an identification mark on each cam follower
to show the location. Remove cam follower (8),
cam follower (9), and cam follower (10) cam
follower body (4).
7. Remove shims (7) from each cam follower
assembly.Note the position of each shim for
installation purposes.
160 UENR4544
Note: The components must be reinstalled in the

used components.
i06511735
Lifter Group - Assemble

(Cam Followers)
Assembly Procedure
Table 50
Required Tools
A - Loctite 242 1
NOTICE
component life.
1. Ensure that all components are clean and free

from wear or damage.The components must be Illustration 322 g06005781
reinstalled in the original location and
orientation. Do not interchange used
components.
UENR4544 161
End By:
a. Install the cam followers. Refer to Disassembly
and Assembly, “Lifter Group - Install (Cam
Followers)” for the correct procedure.
i06511737
Lifter Group - Install

(Cam Followers)
NOTICE
component life.
1. If necessary, install new dowels into the

crankcase.Do not replace the dowels unless the
dowels are damaged.
2. Ensure that the cam followers are clean and free
Illustration 323 g06004712 from wear or damage. Clean the gasket surface of
the crankcase and the cam follower assembly.
2. Position cam follower (8), cam follower (9), and
Note: Ensure that the debris does not enter the
cam follower (10) into cam follower body (4). crankcase.
Ensure that the cam followers are installed into the
original position. 3. Lubricate the lobes of the camshaft and the rollers
3. Install shims (7) between each cam follower of the cam followers with clean engine oil.
assembly. Ensure that the shims are installed into
the original position.
4. Align and install shaft (6) to cam follower body (4)
and the cam followers. Support the weight of the
cam followers as the shaft is installed.
5. Ensure correct alignment of shaft (6) to cam
follower body (4).
6. Apply Tooling (A) to the threads of Allen head bolt
(3) (not shown) and Allen head bolt (5).
7. Install Allen head bolts (3) (not shown) and Allen
head bolt (4) into body (4). Tighten the Allen head
bolts to a torque of 67 N·m (50 lb ft). Ensure that
both cam followers are free to move. Refer to
specifications, “Camshaft” for more information on
end play.
8. Position jet (1) onto cam follower (9). Ensure that
the jet is correctly orientated. Apply Tooling (A) to
the threads of Allen head bolt (2). Install the Allen
head bolt to the jet. Tighten the Allen bolt to a
torque 9 N·m (80 lb in).
162 UENR4544
Start By:
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel
Housing - Remove and Install” for the correct
procedure.
b. Remove the cam followers. Refer to
Disassembly and Assembly, “Lifter Group -
c. Remove the camshaft gear. Refer to
Disassembly and Assembly, “Gear Group
NOTICE
component life.
4. Install new gasket (3) (not shown). Align the cam

follower to the dowels in the crankcase. Install the
assembly of cam follower (1) to the crankcase.
50 N·m (37 lb ft).
i06511768
Camshaft - Remove
Removal Procedure 1. Remove allen head bolts (1) and thrust plate (2).
Table 51 2. Ensure that Tooling (A) is clean and free from
Required Tools burrs. Install Tooling (A) to the nose of camshaft
Part Description Qty
(3).
Tool Part Number
A T6253/142 Camshaft Guide Tool 1
UENR4544 163
6. Remove O-ring seal (6) from cover (5).
i06511769
Camshaft - Install
Table 52
Required Tools
Tool Part Number Part Number Qty
A T6253/142 Camshaft Guide Tool 1
NOTICE
component life.
Typical example
1. Ensure that the camshaft is clean and free from
3. Use a long wooden drift to push on Tooling (A). wear or damage. Refer to Specifications,
Carefully push camshaft (3) out of the rear of the “Camshaft” for more information.
engine. Use a suitable sling to support the 2. Inspect the camshaft bearings for wear or damage.
camshaft during the removal procedure. If necessary, replace the camshaft bearings. Refer
4. Lift the camshaft from the engine. The weight of to Disassembly and Assembly, “Camshaft
the camshaft is approximately 70 kg (155 lb). Bearings - Remove” and Disassembly and
Place the camshaft on a suitable support. If Assembly, “Camshaft Bearings - Install” for the
necessary, remove Tooling (A) from the camshaft. correct procedures.

Typical example
5. Remove bolts (4) and remove cover (5).
164 UENR4544
3. Ensure that Tooling (A) is clean and free from

burrs. Install Tooling (A) to the nose of camshaft
(3).
4. Use a suitable lifting device to lift the camshaft into
position. The weight of the camshaft is
5. Align Tooling (A) with the rear camshaft bearing.
Carefully push camshaft (3) into the engine. Use a
suitable sling to support the camshaft during the
installation procedure.
6. When camshaft (3) is in the correct position,
remove Tooling (A).
8. Position a new O-ring seal (6) onto cover (5).

9. Position cover (5) onto the cylinder block. Install
bolts (4). Tighten the bolts to a torque of 27 N·m
(20 lb ft).
End By:
a. Install the camshaft gear. Refer to Disassembly
and Assembly, “Gear Group (Front) - Install”
7. Lubricate thrust plate (2) with clean engine oil. for the correct procedure.
Install the thrust washer and install Allen head
bolts (1). Tighten the Allen head bolts to a torque b. Install the cam followers. Refer to Disassembly
of 47 N·m (35 lb ft). and Assembly, “Lifter Group - Install” for the
correct procedure.
c. Install the flywheel housing. Refer to
procedure.
i06511770
Camshaft Bearings - Remove
Removal Procedure
Table 53
Required Tools
Camshaft Bearing Removal/

A T6253/199 1
Fitting Tool
UENR4544 165
Start By: 2. Tighten the nut on Tooling (A) to pull camshaft

bearing (1) from the crankcase.
a. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove” for the
i06511771
correct procedure.
NOTICE
Camshaft Bearings - Install
component life. Installation Procedure
Table 54
Required Tools
Camshaft Bearing Removal/

A T6253/199 1
Fitting Tool
NOTICE
component life.
1. Clean the bearing housing in the crankcase.

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

engine oil. Install Tooling (A) to the appropriate
camshaft bearing.
Note: Ensure that Tooling (A) is correctly aligned with

the camshaft bearing and with the crankcase.
166 UENR4544

Alignment of the oil groove
3. Tighten the nut on Tooling (A) to pull camshaft

bearing (1) into the crankcase. Install the camshaft
bearing so that bearing is central in the bearing
housing. Ensure that oil Groove (Y) is aligned with
the oil hole in the crankcase.
End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install” for the correct
procedure.
i06511724
Engine Oil Pan - Remove

Removal Procedure
NOTICE
component life.
Illustration 333 g01859333 NOTICE

2. Position new camshaft bearing (1) on Tooling (A). nance, testing, adjusting and repair of the product.
Lubricate the threads on Tooling (A) with clean Be prepared to collect the fluid with suitable contain-
engine oil. Assemble Tooling (A). ers before opening any compartment or disassem-
Note: The camshaft bearing should be installed with
Joint (X) in the twelve o'clock position. The locking Dispose of all fluids according to local regulations
tabs should face toward left side of the engine. View and mandates.
the engine from rear.
UENR4544 167
Engine Oil Pan

1. Drain the engine oil into a suitable container for
storage or disposal. Refer to Operation and
Change.” for the correct procedure.
5. Remove the dipstick and tube (13) from engine oil

pan (9).
6. Remove bolts (10) (not shown) from solenoid
mounting bracket (11) for the starting motor.
Position the solenoid mounting bracket for the
starting motor away from the engine oil pan.
Note: Note the position of any bracket.
7. Remove bolts (12) from engine oil pan (9).

Note: Note the position of bolts of different lengths
for installation purposes.
2. Remove bolts (5) and bolts (7).

3. Remove tube assembly (7) from engine oil pump
(1) and the engine oil pan. Remove O-ring seal (8)
(not shown).
4. Remove O-ring seal (4) (not shown) and spacer (3)
(not shown). Remove O-ring seal (2) (not shown).
8. Support the weight of engine oil pan (9). The

weight of the engine oil pan is approximately 60 kg
(130 lb).
9. Lower engine oil pan (9) and then remove the
engine oil pan. Remove gasket (14).
168 UENR4544
Suction Pipe and Strainer NOTICE

component life.
Suction Pipe and Strainer

1. Ensure that the components of the engine oil pan
and suction pipe are clean and free from damage.
1. Remove bolts (15) and loosen the nuts on clamp

(16).
2. Remove suction pipe (17) and strainer (18) from
engine oil pan (9).
i06511725
Engine Oil Pan - Install Illustration 339 g06008492
2. Install suction pipe (17) and strainer (18) to engine

oil pan (9).
Installation Procedure 3. Install bolts (15) finger tight. Tighten bolts (15) to a
Table 55 torque of 47 N·m (35 lb ft).
Required Tools
4. Tighten the nuts on clamp (16) to a torque of
Tool Part Number Part Description Qty 25 N·m (18 lb ft).
A -
1 5. Ensure that suction pipe (17) and strainer (18) are
Grease installed correctly in the engine oil pan.
Loctite 518 Gasket and
B - 1
Flange Sealant Engine Oil Pan
Guide Studs
C - 2 1. Ensure that the gasket surfaces of the engine oil
M10 by 50 mm
pan and the crankcase are clean.
D - 1
Nut lock
UENR4544 169

Typical example
Note: If a new gasket has been installed to the timing

case, to the back plate or to the flywheel housing,
ensure that the gasket is flush with the crankcase.
2. Apply Tooling (B) to the face of the crankcase at

Positions (X) and Positions (Y). Install Tooling (C)
to each end of the crankcase.
3. Position a new gasket (14) on oil pan (9).
Note: Ensure the correct orientation of the gasket.
4. Use a suitable lifting device to lift engine oil pan (9)

into position. The weight of the engine oil pan is
approximately 60 kg (130 lb). Align the engine oil
pan with Tooling (C). Carefully install the engine oil
pan.
5. Install bolts (12) finger tight to engine oil pan (9).
6. Remove Tooling (C) and install remaining bolts
(12) finger tight to engine oil pan (9).
7. Position solenoid mounting bracket (11) for the
starting motor and install bolts (10) (not shown)
finger tight.
47 N·m (35 lb ft).
9. Install the dipstick and tube (13) to engine oil pan
(9). Tighten tube (13) securely.
170 UENR4544
Start By:
a. Remove the pistons and connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Remove” for the
correct procedure.
NOTICE
component life.
NOTICE
Illustration 343 g06008455 tained during performance of inspection, mainte-
10. Apply Tooling (A) to a new O-ring seal (2), a new Be prepared to collect the fluid with suitable contain-
O-ring seal (4) and a new O-ring seal (8). bling any component containing fluids.
11. Position a new O-ring seal (2) (not shown) and
install spacer (3) (not shown) onto engine oil pan. and mandates.
Position a new O-ring seal (4) (not shown) onto
spacer (3) (not shown).
1. Use Tooling (A) to rotate the crankshaft. Rotate the
12. Position a new O-ring seal (2) (not shown) onto crankshaft until there is sufficient clearance to
pipe (7). Install pipe (7) onto engine oil pump (1) install Tooling (B).
and engine oil pan.
13. Install bolts (7) to engine oil pump (1) hand tight.
14. Apply Tooling (D) to the threads of bolts (5).
Install bolts (5) hand tight.
17. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter- Change” for the correct procedure.
18. Prime the engine oil system. Refer to Operation
and Maintenance Manual, “Before Starting the
Engine” for the correct procedure.
i06511727
Cylinder Liner - Remove
Removal Procedure
2. Follow Step 2.a through Step 2.c to assemble
Table 56
Tooling (B) to the cylinder liner.
Required Tools
Part Description Qty

a. Position the lower clamping plate in the bottom
Tool Part Number
of the cylinder liner. Position the upper
A SE253 Engine Turning Tool 1 clamping plate in the top of the cylinder liner.
B T6253/152 Liner Extractor 1
b. Install the bolts to the clamping plates. Tighten
the bolts securely.
UENR4544 171
c. Locate the frame in the cylinder head bolt

holes. Lubricate the threads with clean engine
oil.
3. Tighten the forcing bolt on Tooling (B) to pull
cylinder liner (1) from the crankcase.
Note: A small quantity of coolant and accumulated
debris will be released when the liner is removed
from the crankcase. Ensure that the crankshaft is
protected from the debris.
4. Lift Tooling (B) and the cylinder liner from the

crankcase. The weight of Tooling (B) and the
cylinder liner is approximately 45 kg (100 lb).
Remove the cylinder liner from Tooling (B).
5. Remove O-ring seals (2) from cylinder liner (1).
i06511728
Cylinder Liner - Install
Table 57
Required Tools

C - 1
Grease
D - Loctite 638 1
T6253/200 Liner Clamp Kit 1
E - Cylinder Head Bolts 2
- Spacers 2
NOTICE
component life.
172 UENR4544
1. Clean the interior of the crankcase. Ensure that the

seat for the cylinder liner is clean, dry, and free
from rust or sealant. Ensure that the cylinder liner
is clean and dry. If a used cylinder liner is installed,
ensure that the cylinder liner is free from rust or
sealant.

6. Install Tooling (E).

2. Install new O-ring seals (2) to cylinder liner (1).
Note: Install Tooling (E) so that the Tooling does not
foul the dowels in the crankcase.
7. Use Tooling (E) to push cylinder liner (1) into the

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

top of the cylinder liner will sit below the face of the
crankcase.
8. Check Dimension (X).
Dimension (X)
. . . 2.07 mm to 2.20 mm ((0.082 inch to 0.087 inch))
3. Apply Tooling (C) to Bore (Z) in the crankcase.

4. Apply Tooling (D) to Face (Y) on the crankcase.
5. Carefully install liner (1) to the crankcase. Push the
liner into the crankcase by hand until the O-ring
seals contacts the bottom of the crankcase.
Note: Resistance will be felt as the O-ring seals
contacts the bottom of the crankcase.
UENR4544 173
End By:
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install” for the correct
procedure.
i06511694
Piston Cooling Jets - Remove

and Install
Removal Procedure
Table 58
Required Tools
A SE253 Engine Turning Tool 1

Start By:
a. Remove the engine oil coolers. Refer to
Cooler - Remove” for the correct procedure.
NOTICE
component life.
NOTICE
and mandates.

1. Use Tooling (A) to rotate the crankshaft so that the
piston of the appropriate cylinder is at the top 2. Remove bolt (3) and remove plate (2).
center position.
3. Rotate piston cooling jet (1) clockwise by 90
degrees. Rotate into Position (C). Withdraw the
cooling jet from the crankcase.
4. Remove O-ring seal (4) from piston cooling jet (1).
5. Remove plug (5) and remove O-ring seal (6).
6. If necessary, repeat Step 1 through Step 5to
remove remaining piston cooling jets (1) from the
crankcase.
174 UENR4544
Table 59
Required Tools
B T9142/21 Drift 1
NOTICE
component life.
UENR4544 175
End By:
a. Install the engine oil coolers. Refer to
Cooler - Install” for the correct procedure.
b. Install the Aftercooler. Refer to Disassembly
and Assembly, “Aftercooler- Remove and
i06511697
Pistons and Connecting Rods

- Remove
Removal Procedure
Table 60
Required Tools
1. lubricate O-ring seal (4) and O-ring seal (6) with
clean engine oil.
B T6253/212 Piston Crown Handle 1
2. Install O-ring seal (4) to piston cooling jet (1).
Install O-ring seal (6) to plug (5)
Start By:
3. Install cooling jet (1) into Position (C). Rotate the
cooling jet counterclockwise by 90 degrees. a. Remove the cylinder heads. Refer to
4. Temporarily install bolt (3) to piston cooling jet (1). Remove” for the correct procedure.
5. Position Tooling (B) onto piston cooling jet (1). b. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
6. Use Tooling (B) to install the piston cooling jet into Jets - Remove and Install” for the correct
the crankcase. Remove tooling (B) and bolt (3). procedure.
7. Install plug (5) to cooling jet (1). Ensure that the
NOTICE
plug is correctly installed into the piston cooling jet. Keep all parts clean from contaminants.
8. Install plate (2) and install bolt (3). Tighten the bolt Contaminants may cause rapid wear and shortened
to a torque of 47 N·m (35 lb ft). component life.
9. If necessary, repeat Step 1 through Step 8 to
install remaining piston cooling jets (1) into the 1. Use Tooling (A) to rotate the crankshaft to a
crankcase. convenient position.
2. Remove the carbon ridge from the top of the
cylinder liner bore. Remove the carbon from the
piston crown.
176 UENR4544
3. Remove bolts (3) and remove inspection cover (2).

Remove O-ring seal (1).
Note: The connecting rod and connecting rod cap

have an etched Number (X) on the side. The number
on connecting rod (6) and the number on connecting
rod cap (5) must match. Ensure that the connecting
rod and the connecting rod cap are marked for the
correct location. If necessary, make a temporary
mark on the connecting rod and the connecting rod
cap to identify the cylinder number.
4. Use Tooling (A) to carefully rotate the crankshaft.

Rotate the crankshaft until the appropriate piston
is just after the top center position.
5. Remove connecting rod bolts (4) and connecting
rod cap (5) from connecting rod (6).
6. Position Tooling (B) onto the crown of piston (7).
Carefully expand Tooling (B) into the recess of the
piston.
UENR4544 177
Note: Ensure that Tooling (B) is installed to the piston

securely.
7. Use Tooling (B) to remove the piston assembly

from the cylinder liner bore.
Note: Be careful not to damage the cylinder liner or

the crankshaft journal during the removal of the
piston assembly.
8. Temporarily install connecting rod cap (5) and

connecting rod bolts (4) to connecting rod (6) to
keep the bearing shell in position.
i06511698

- Disassemble
Table 61
Required Tools
C T6253/258 Circlip Pliers 1 Illustration 358 g06008890
D T6253/256 Piston Ring Pliers 1

2. Remove connecting rod bolts (5) and connecting
E T6253/159 Small End Bush Tool 1 rod cap (4) from connecting rod (1).
3. Remove lower bearing shell (3) from connecting
Start By: rod cap (4). Remove upper bearing shell (2) from
a. Remove the pistons and the connecting rods. connecting rod (1).
and Connecting Rods - Remove” for the
correct procedure.
NOTICE
component life.
1. Make a temporary mark on the components of the

piston and connecting rod assembly to show the
location and the orientation. Marking the
components will ensure that the components of
each piston and connecting rod assembly can be
reinstalled in the original cylinder. Do not
interchange used components.
178 UENR4544
4. Use Tooling (D) to remove compression ring (7) 7. Inspect small end bush (13) for wear or for
and compression ring (8), and oil control ring (9) damage. Refer to Specifications, “Pistons and
from piston (12). Rings” for more information. If the small end bush
is damaged or worn beyond the specified limits,
Note: Identify the position and the orientation of the use Tooling (E) to remove the small end bush from
compression rings and the oil control ring.
connecting rod (1).
5. Use Tooling (C) to remove circlips (10) from piston
i06511700
(12).
6. Remove piston pin (11) and connecting rod (1) Pistons and Connecting Rods
from piston (12).
- Assemble
Note: If the piston pin cannot be removed by hand,
heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Note the orientation of the connecting
rod to the piston. Assembly Procedure
Table 62
Required Tools
C T6253/258 Circlip Pliers 1
D T6253/256 Piston Ring Pliers 1
E T6253/159 Small End Bush Tool 1
NOTICE
component life.
1. Follow Step 1.a through Step 1.e to inspect the

pistons and the connecting rods.
UENR4544 179
a. Carefully remove the carbon deposits from the

piston. Visually check the piston for cracks,
signs of seizure or other damage.
b. Inspect piston ring grooves for wear. Refer to

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

cracks. Inspect the connecting rod for wear Illustration 362 g06008893
and for distortion. Refer to Specifications,
“Connecting Rod” for more information. If the
connecting rod requires replacement, ensure
that the weight of the new connecting rod is
the same weight as the original connecting
rod.

The correct orientation of the piston and connecting
rod
(W) Cut out for the piston cooling jet
(X) Camshaft
(Y) Piston cooling jet
Illustration 361 g06008899 (1) Connecting rod assembly
2. If the small end bush requires replacement, use

Tooling (E) to install small end bush (13) to
connecting rod (1).
Note: A replacement small end bush is supplied,
finished to the correct size.
180 UENR4544
b. Use Tooling (D) to install oil control ring (9)

over the spring.
Note: Ensure that the central wire is 180 degrees
from the ring gap.
c. Use Tooling (D) to install intermediate

compression ring (8) into the second groove in
piston (12). The identification “TOP” must be
upward.
d. Use Tooling (D) to install top compression ring

(7) into the top groove in piston (12). The
identification “TOP” must be upward
e. Position the piston ring gaps at 120 degrees

away from each other.

The location and orientation of the piston rings
(7) Top compression ring
(8) Intermediate compression ring
(9) Oil control ring
(12) Piston
3. Lubricate the small end bush and the bores in

piston (12) with clean engine oil.
4. Ensure the correct orientation of connecting rod
(1).Install connecting rod (1) to piston (12). Refer
to illustration 363 for more information. Lubricate
piston pin (11) with clean engine oil. Slide the
piston pin into position.
Note: If the piston pin cannot be installed by hand,
heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F).
5. Use Tooling (C) to install new circlips (10). Ensure

that the circlips are correctly seated into the
grooves.
6. Follow Steps 6.a through 6.e to install the piston
rings to the piston (12).
a. Position the spring for oil control ring (9) into

the oil ring groove in piston (12). The central
wire must be located inside the end of the
spring.
UENR4544 181
8. Temporarily install connecting rod cap (4) to

connecting rod (1) to keep the bearings in position.
Loosely install new connecting rod bolts (5).
End By:
a. Install the pistons and the connecting rods.
and Connecting Rods - Install” for the correct
procedure.
i06511701

- Install
Table 63
Required Tools
B T6253/212 Piston Crown Handle 1
F T6253/139 Piston Ring Compression Tool 1

G SE-671K 30 Degree Indicator Socket Tool 1
NOTICE
component life.

Location of the bearing tab
7. Install upper bearing shell (2) to connecting rod (1).

Install lower bearing shell (3) to connecting rod
cap (4). Ensure that the upper bearings shell and
lower bearing shell are correctly seated and that
the tabs are located in the slots (Z). Refer to
illustration 366 .
182 UENR4544
Note: Ensure that Tooling (F) is installed correctly

and that the piston can easily slide from the tool.
Ensure that the piston and the connecting rod are
installed in the correct cylinder.
1. Installation of the piston and connecting rod

assembly require two trained personnel. Use
Tooling (A) to rotate the crankshaft carefully.
Rotate the crankshaft until the appropriate
crankshaft pin is just after the top center position. (W) Cut out for the piston cooling jet
(X) Camshaft
(Y) Piston cooling jet
2. Position Tooling (B) onto the crown of piston (7). (6) Connecting rod
Carefully expand Tooling (B) into the recess of the
piston. Remove the connecting rod bolts and the 6. Ensure that the piston is correctly oriented. Refer
connecting rod cap from the connecting rod. to illustration 368 .
Note: Ensure that Tooling (B) is installed to the piston 7. Carefully push the piston and the connecting rod
securely. into the cylinder liner bore. At the same time, guide
the connecting rod onto the pin of the crankshaft.
3. Apply clean engine oil to the cylinder liner bore, to
Take care not to displace the bearing shells.
the piston rings and to the outer surface of the
piston. Note: Be careful not to damage the cylinder liner, the
bearing shells, or the crankshaft during installation of
4. Lubricate the bearing shells and lubricate the
the piston and the connecting rod.
crankshaft pin with clean engine oil. Lubricate the
threads and the underside of the heads of the new 8. Remove Tooling (F).
connecting rod bolts with clean engine oil.
Note: Install the bearing shells dry when clearance
checks are performed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check” for the
correct procedure. Apply clean engine oil on the big
end bearings for final assembly.
5. Ensure that the gaps for the piston rings are at 120
degrees away from each other. Position Tooling
(F) onto the piston to compress the piston rings.
Carefully position the piston and the connecting
rod into the cylinder liner bore.
UENR4544 183
11. Use the following method to tighten the

connecting rod bolts to the correct torque.
a. Tighten connecting rod bolts (4) to a torque of

110 N·m (82 lb ft).
b. Install Tooling (G) to connecting rod bolt (4).

Apply light pressure to the wrench. Set the
leading edge of Tooling (G) in line with the
center of the connecting rod. Turn connecting
rod bolt (4) through 30 degrees. The trailing
edge of Tooling (G) is now in line with the
center of the connecting rod.
c. Reposition Tooling (G) so that the leading

edge of Tooling (G) is in line with the center of
the connecting rod. Turn connecting rod bolt
9. The connecting rod and connecting rod cap have
(4) through an additional 30 degrees. The
an etched Number (X) on the side. The number on
trailing edge of Tooling (G) is now in line with
connecting rod (6) and the number on connecting
the center of the connecting rod.
rod cap (5) must match. Position connecting rod
cap (5) on the connecting rod.
NOTICE
Discard all used connecting rod bolts.
10. Install the new connecting rod bolts (4) to

connecting rod cap (5) hand tight.
184 UENR4544
End By:
a. Install the piston cooling jets. Refer to
Jets - Remove and Install” for the correct
procedure.
b. Install the cylinder heads. Refer to
i06511702
Crankshaft Main Bearings -

Remove and Install
Removal Procedure
Start By:
Illustration 372 g06009075 a. Remove the crankshaft and the thrust washers.
Using feeler gauges to check the side float of the “Crankshaft - Remove” for the correct
connecting rods procedure.
12. Check the side float of the connecting rods. NOTICE

Connecting rod side float
. . . 0.36 mm to 0.69 mm ((0.014 inch to 0.027 inch)) Contaminants may cause rapid wear and shortened
component life.
1. Remove upper main bearings (1) from the

crankcase.
Illustration 373 g06008568 Note: The upper main bearings have a groove and
two oil holes.
13. Install O-ring seal (1) and inspection plate (2).
Install bolts (3). Tighten bolts to a torque of 47 N·m
(35 lb ft).
UENR4544 185
Note: The lower main bearings are plain bearings

that have no oil holes.
2. Remove lower main bearings (2) from the main

bearing caps. Illustration 377 g06009901
Note: The lower main bearings are plain bearings 3. Install upper main bearings (1) to the crankcase.
that have no oil holes.
Note: The upper main bearings have a groove and
two oil holes.
NOTICE
component life.
1. Inspect the main bearings for wear or for damage.

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

the main bearings and the main bearing bolts should
be replaced.
2. Install lower main bearings (2) to the main bearing

caps.
186 UENR4544
End By:
a. Install the crankshaft and the thrust washers.
“Crankshaft - Install” for the correct procedure.
i06511703
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the piston cooling jets. Refer to
Jets - Remove and Install”.
b. Remove the pistons and connecting rods.
and Connecting Rods - Remove”.
c. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan - 2. Rotate the crankshaft so that the center balance
Remove”.
weights are in the horizontal position.
d. Remove the back plate. Refer to Disassembly
3. Remove allen head bolts (3).
and Assembly, “Engine Support (Front) -
Remove and Install”. Note: Check the marking on each bearing cap.
e. Remove the flywheel housing. Refer to
Disassembly and Assembly, “Flywheel 4. Remove main bearing bolts (1).
Housing - Remove and Install”. 5. Remove main bearing caps (2).
NOTICE
component life.
1. The engine should be placed in the inverted

position. The weight of the engine is approximately
3350 kg (7385 lb).
Note: Place the engine on a suitable surface to avoid

damage to the machined faces of the crankcase.
6. Remove thrust washers (4) from the crankcase.

Note: The crankshaft has two thrust washers. The
thrust washers are on each side of the rear main
bearing. Note the orientation of the thrust washers.
UENR4544 187
1. Inspect the crankshaft for wear and for damage.

Refer to Specifications, “Crankshaft” for more
information.
2. Install the main bearings to the crankcase and to
the main bearing caps. Refer to Disassembly and
Assembly, “Crankshaft Main Bearings - Remove
Note: Install the main bearings dry when clearance
checks are performed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check” for the
correct procedure. Apply clean engine oil on the face
of the main bearings for final assembly.

Typical example
7. Attach a suitable sling and a lifting device to

crankshaft (5). Attach the sling around the center
balance weights of the crankshaft. The weight of
the crankshaft is approximately 356 kg (785 lb).
8. Carefully lift crankshaft (5) out of the crankcase.
Place the crankshaft on a suitable support.
9. Remove the crankshaft main bearings. Refer to
Disassembly and Assembly, “Crankshaft Main
Bearings - Remove and Install” for the correct
procedure.
i06511704
Typical example
Crankshaft - Install 3. Attach a suitable sling and a lifting device to

crankshaft (5). Attach the sling around the center
balance weights of the crankshaft. The weight of
the crankshaft is approximately 356 kg (785 lb).
Installation Procedure 4. Carefully lift crankshaft (5) into the crankcase.
Table 64
Note: The crankshaft should be installed with the
Required Tools
center balance weights in the horizontal position.
21825617 Dial Indicator 1
A
NOTICE
component life.
188 UENR4544
5. Lubricate thrust washers (4) with clean engine oil.

Install the thrust washers to the crankcase.
Note: The crankshaft has two thrust plates. The

thrust washers are on each side of the rear main
bearing. Install the thrust washers with the grooves
toward the crankshaft.

Identification of the main bearing caps
6. The crankcase and main bearing cap have a

Number (X) on the bottom. The number on main
bearing cap (2) must match the corresponding
number on the crankcase. Install the main bearing
caps to the crankcase.
7. Lubricate the underside of the head and the
threads of main bearing bolts (1) with clean engine
oil. Install the main bearing bolts finger tight.
8. Lubricate the underside of the head and the
threads of Allen head bolts (3) with clean engine
oil. Install the Allen head bolts finger tight.
UENR4544 189
e. Tighten Allen head bolts (3) to a torque of

f. Ensure that the crankshaft rotates freely.
9. Use the following method to tighten the main

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

b. Tighten main bearing bolts (1) to a torque of
c. Tighten main bearing bolts (1) to a torque of Checking the end play of the crankshaft
shown in Illustration 385 . 10. Use Tooling (A) to check the crankshaft end play.
d. Tighten main bearing bolts (1) to a torque of Crankshaft end play (new thrust washers)
783 N·m (580 lb ft) in the sequence that is . . . 0.13 mm to 0.51 mm ((0.005 inch to 0.020 inch))
Maximum crankshaft end play (service limit)
. . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm ((0.025 inch))

Sequence for tightening the side Allen head bolts
190 UENR4544
End By:
a. Install the flywheel housing. Refer to
procedure.
b. Install the back plate. Refer to Disassembly
and Assembly, “Engine Support (Front) -
c. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install” for the correct
procedure.
d. Install the piston cooling jets . Refer to
Jets - Remove and Install” for the correct
procedure. 1. Make marks in Position (X) on crankshaft gear (2)
and crankshaft (1) in the upward position.
e. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Install” for the 2. Use Tooling (A) to pull crankshaft gear (2) from
correct procedure. crankshaft (1).
i06511705 Installation Procedure

Table 66
Crankshaft Gear - Remove and Required Tools
Install Tool Part Number Part Description Qty
B - Hot Plate 1
Removal Procedure
Table 65
NOTICE
Required Tools
Tool Part Number Part Description Qty component life.
A - Puller 1
Start By:
a. Remove the timing gears. Refer to
Disassembly and Assembly, “Gear Group
NOTICE
component life.
1. Use Tooling (B) to heat crankshaft gear (1) to

250 °C (480 °F).
Note: Do not use a torch to heat the crankshaft gear.
UENR4544 191
Note: The measurements should be within

specifications and the correct bearings should be
Always wear protective gloves when handling used. If the crankshaft journals and the bores for the
parts that have been heated. block and the rods were measured during
disassembly, no further checks are necessary.
2. Align timing Mark (X) on crankshaft gear (2) with However, if the technician still wants to measure the
timing Mark (X) on crankshaft (1). Install the bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
crankshaft gear to the crankshaft.
small diameters if clearances are less than 0.10 mm
Note: Ensure that the crankshaft gear is seated (0.004 inch).
against the shoulder on the crankshaft.
NOTICE
End By: Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
a. Install the timing gears. Refer to Disassembly
and Assembly, “Gear Group (Front) - Install” The technician must use Tooling (A) correctly. The
for the correct procedure. following points must be remembered:
i05980323 • Ensure that the backs of the bearings and the

bores are clean and dry.
Bearing Clearance - Check • Ensure that the bearing locking tabs are properly
seated in the tab grooves.
• The crankshaft must be free of oil at the contact
Measurement Procedure points of Tooling (A).
Table 67
1. Put a piece of Tooling (A) on the crown of the
Required Tools
bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the
Plastigauge (Green) edge of the bearing.
- 0.025 to 0.076 mm 1
(0.001 to 0.003 inch) 2. Use the correct torque-turn specifications in order
Plastigauge (Red) to install the bearing cap. Do not use an impact
- 0.051 to 0.152 mm 1 wrench. Be careful not to dislodge the bearing
(0.002 to 0.006 inch) when the cap is installed.
A
Plastigauge (Blue)
Note: Do not turn the crankshaft when Tooling (A) is
- 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
installed.
Plastigauge (Yellow) 3. Carefully remove the cap, but do not remove

- 0.230 to 0.510 mm 1 Tooling (A). Measure the width of Tooling (A) while
(0.009 to 0.020 inch) Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 390 .
NOTICE
component life.
Note: Perkins does not recommend the checking of

the actual clearances of the bearing shells
particularly on small engines. Checking of the actual
clearances of the bearing shells is because of the
possibility of obtaining inaccurate results and of
damaging the bearing shell or the journal surfaces.
Each Perkins bearing shell is quality checked for
specific wall thickness.
192 UENR4544
1. Drain the coolant from the cooling system to a

level that is below the coolant temperature switch.
Use a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change” for the correct
procedure.

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 Illustration 391 g06011602
within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and 2. Disconnect harness assembly (1) from coolant
Specifications Manual, “Main Bearing Journal” for the temperature switch (2).
correct clearances.
3. Remove coolant temperature switch (2) from
i06511706 thermostat housing (4).
4. Remove sealing washer (3) (not shown) from
Coolant Temperature Switch - coolant temperature switch (2).
Remove and Install Installation Procedure
Table 68
Required Tools
Removal Procedure
NOTICE Loctite 542 Hydraulic
Keep all parts clean from contaminants. A - 1
Thread Sealant

component life.
NOTICE
NOTICE Contaminants may cause rapid wear and shortened
Care must be taken to ensure that fluids are con- component life.
and mandates.
UENR4544 193
NOTICE
and mandates.
1. Install a new sealing washer (3) (not shown) to

coolant temperature switch (2). Apply Tooling (A)
to the threads of coolant temperature switch (2).
2. Install coolant temperature switch (3) into
thermostat housing (2). Tighten the coolant
temperature switch to a torque of 30 N·m
(266 lb in).
3. Connect harness assembly (1) to coolant
temperature switch (2).
4. Fill the cooling system to the correct level. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.
i06511709
1. Disconnect harness assembly (4) from engine oil
Engine Oil Pressure Switch - pressure switch (3).
Remove and Install 2. Remove engine oil pressure switch (3) from
adapter (2).
3. If necessary, remove adapter (2) from the engine
Removal Procedure cylinder block. Follow Step 3.a through Step 3.b to
remove the adapter from the engine cylinder
NOTICE block.
a. Remove adapter (2) from the engine cylinder
Contaminants may cause rapid wear and shortened block.
component life.
b. Remove sealing washer (1).
194 UENR4544
Table 69
Required Tools
Loctite 542 Hydraulic

A - 1
Thread Sealant
NOTICE
component life.
1. If necessary, Install adapter (2) to the engine

cylinder block. Follow Step 3.a through Step 3.b to
install the adapter to the engine cylinder block.
a. Install a new sealing washer (1) to adapter (2).
b. Apply Tooling (A) to the threads of adapter (2).

Install adapter (2) to the engine cylinder block.
c. Tighten the adapter to a torque of 47 N·m

(35 lb ft).
2. Apply Tooling (A) to the threads of oil pressure

switch (3). Install engine oil pressure switch (3) to
adapter (2). Tighten the engine oil pressure switch
to a torque of 9.5 N·m (84 lb in).
3. Connect harness assembly (4) to engine oil
pressure switch (3).
i06511710
Engine Oil Pressure Switch -

Remove and Install
(Alternator Warning Lamp)
Removal Procedure
NOTICE
component life.
UENR4544 195
NOTICE
and mandates.
1. Apply Tooling (A) to the threads of engine oil

pressure switch (2). Install the engine oil pressure
switch to engine oil filter base (3). Tighten the
engine oil pressure switch to a torque of 9.5 N·m
(84 lb in).
2. Connect harness assembly (1) to engine oil
Illustration 395 g06011491 i06545810
1. Disconnect harness assembly (1) from engine oil Temperature Sensor (Exhaust)
- Remove and Install
2. Remove engine oil pressure switch (2) from engine
oil filter base (3). (Exhaust Temperature
Installation Procedure Thermocouples)
Table 70
Required Tools
Removal Procedure
Loctite 542 Hydraulic NOTICE

A -
Thread Sealant
1 Keep all parts clean from contaminants.
component life.
NOTICE
1. Exhaust temperature thermocouple can be
installed in either the exhaust elbow or the rear
component life.
sections of the exhaust manifold. Removal and the
installation procedures are similar for both
positions.
196 UENR4544

Typical example Typical example
2. Disconnect harness assembly (4) from the engine 2. If necessary, apply Tooling (A) to threads adaptor
harness assembly. (3). Install the adaptor exhaust elbow (1). Tighten
the adaptor to a torque of 20 N·m (177 lb in).
3. Remove exhaust temperature thermocouple (2)
from exhaust elbow (1). 3. Apply Tooling (A) to threads exhaust temperature
thermocouple (2). Install the exhaust temperature
4. If necessary, remove adaptor (3) exhaust elbow
thermocouple to exhaust elbow (1). Tighten the
(1).
adaptor to a torque of 20 N·m (177 lb in).
Installation Procedure 4. Connect harness assembly (4) to the engine
Table 71 harness assembly.
Required Tools
i06511712
Loctite C5-A Anti-Sieze Engine Speed Sensor -

A - 1
Compound
Remove and Install
NOTICE
(Overspeed Sensor)
component life. Removal Procedure
NOTICE
1. Ensure that all components are free from wear or Keep all parts clean from contaminants.
damaged.
component life.
UENR4544 197
1. Disconnect harness assembly (1) from engine

overspeed sensor (3).
2. Loosen locknut (4) and remove engine overspeed
sensor (3) from flywheel housing (2).
Table 72
Required Tools
NOTICE
component life.
1. Refer to Operation and Maintenance Manual,

“Speed Sensor - Clean/Inspect” for the correct Illustration 401 g06011472
procedure.
2. Install Tooling (A) to flywheel housing (2).
3. Use Tooling (A) to rotate the engine. Align one
tooth of the flywheel ring gear (5) to the center
position of the tapped hole in flywheel housing (2).
Refer to Illustration 401 .
198 UENR4544
4. Install the engine overspeed sensor (3) into

flywheel housing (2). Screw the engine overspeed
sensor until the engine overspeed sensor just
touches the tooth of the flywheel ring gear.
Unscrew the engine overspeed sensor In a
counterclockwise direction by half a turn. A
clearance of 0.5 mm to 0.8 mm
(0.02 inch to 0.03 inch) will be obtained.
5. Tighten locking nut (4) to a torque of 22 N·m
(195 lb in).
Note: Ensure that engine overspeed sensor (3) does

not turn when locking nut (4) is torqued.
6. Remove Tooling (A) from flywheel housing (2).

7. Connect harness assembly (1) to engine
overspeed sensor (3).
i06511713
Engine Speed Sensor -

Remove and Install
(Engine Speed for Governor
Control) Illustration 402 g06011479
1. Disconnect harness assembly (1) from engine

Removal Procedure speed sensor (3).
NOTICE 2. Loosen locknut (4) and remove engine speed

Keep all parts clean from contaminants. sensor (3) from flywheel housing (2).
Contaminants may cause rapid wear and shortened Installation Procedure
component life.
Table 73
Required Tools
NOTICE
component life.
1. Refer to Operation and Maintenance Manual,

“Speed Sensor - Clean/Inspect” for the correct
procedure.
UENR4544 199
4. Install engine speed sensor (3) into flywheel

housing (2). Screw the engine speed sensor until
the engine speed sensor just touches the tooth of
the flywheel ring gear. Unscrew the engine speed
sensor In a counterclockwise direction by half a
turn. A clearance of 0.5 mm to 0.8 mm
(0.02 inch to 0.03 inch) will be obtained.
5. Tighten locking nut (4) to a torque of 22 N·m
(195 lb in).
Note: Ensure that engine speed sensor (3) does not

turn when locking nut (4) is torqued.
6. Remove Tooling (A) from flywheel housing (2).

7. Connect harness assembly (1) to engine speed
sensor (3).
i06511719
Boost Pressure Sensor

-Remove and Install
Removal Procedure
NOTICE
component life.
2. Install Tooling (A) to flywheel housing (2).

3. Use Tooling (A) to rotate the engine. Align one
tooth of the flywheel ring gear to the center
position (5) of the tapped hole in flywheel housing
(2).
200 UENR4544
1. Disconnect the harness assembly from boost 1. Install a new O-ring seal (2) to boost pressure
pressure sensor (1). sensor (1).
2. Use a deep socket to remove boost pressure 2. Use a deep socket to install boost pressure sensor
sensor (1). (1). Tighten the boost pressure sensor to a torque
of 10 N·m (89 lb in).
3. Remove O-ring seal (2) from boost pressure
sensor (1). 3. Connect the harness assembly to boost pressure
sensor (1).
i06551747
NOTICE
Keep all parts clean from contaminants. V-Belts - Remove and Install
component life. (Fan Drive Belts)
Removal Procedure
NOTICE
component life.

UENR4544 201
6. Rotate nut (4) in a counterclockwise direction to

release the tension on the V-belts.

Typical example
2. Remove pulley guard (1). Refer to the Original
The guards are not shown for clarity.
Equipment Manufacture (OEM) for the correct
procedure.
7. Remove the V-belts from pulley (6), pulley (7), and
3. Remove the cover from aperture (2). Refer to the pulley (8). Lay the V-belts on shaft (9). Lift the V-
Original Equipment Manufacture (OEM) for the belts over pulley (8) and withdraw the V-belts
correct procedure. through the aperture in the guard.
NOTICE
component life.
1. Inspect the V-belts for cracks or contamination. If

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

The guards are not shown for clarity.
4. Loosen nuts (3).

5. Loosen locknut (5).
202 UENR4544

The guards are not shown for clarity. The guards are not shown for clarity.

Typical example Checking Deflection (X) with a spring balance and a
straight edge
2. Ensure that pulley (6), pulley (7), and pulley(8) are
aligned. If necessary, adjust the position of pulley 4. Follow Step 4.a and Step 4.b to adjust the tension
(8) on shaft (9). Refer to Disassembly and of the V-belts.
Assembly, “Vibration Damper and Pulley -
a. Rotate nut (4) in a clockwise direction to
Remove and Install” for more information.
increase the tension on the V-belts.
3. Pass the V-belts through aperture (2). Position the
b. Use a spring balance and a straight edge to
V-belts on pulley (6), pulley (7), and pulley (8).
apply a force of 31 N to 49 N (7 lb to 11 lb) to
each V-belt separately. Apply the force to the
longest free length of the V-belts. Deflection
UENR4544 203
(X) should be 8 mm (0.315 inch).
c. Use a suitable belt tension gauge to check the

tension of the V-belts.
V-belts tension . . . . 24 N to 36 N ((5.4 lb to 8.1 lb))

Note: The tension of the V-belts can be checked
through the aperture in the fan guard.
5. Tighten locknut (5) securely.

7. Install pulley guard (1). Refer to the OEM for the
correct procedure.
8. Install the cover to aperture (2). Refer to Illustration
407 . Refer to the OEM for the correct procedure.
i06551748
2. Loosen captive bolt (2) and captive bolt (6) for
Alternator Belt - Remove and upper guard (3). Remove the upper guard from the
alternator.
Install
lower guard (5). Remove the lower guard from the
alternator.
Removal Procedure


4. Make a temporary mark on belt (9) to show

direction of rotation.
5. Loosen bolt (10).
204 UENR4544
6. Slacken self-locking nut and bolt (8) and Slacken

self-locking nut and bolt (11) from alternator (11)
for alternator (7).
7. Push alternator (7) down ward and remove belt (9)
from the pulley of alternator (7) and the lower
pulley.
1. Ensure that all components are free from wear or
damage. If necessary, replace any component that
is worn or damaged.
7. Install lower guard (5) and tighten captive bolt (1)

and captive bolt (4) to a torque of 10 N·m
(89 lb in).
8. Install upper guard (3) and tighten captive bolt (2)
(89 lb in).
i06511716
2. Ensure that pulley of alternator (7) and the lower

pulley are free from old material. If necessary, use
Alternator - Remove and Install
suitable cleaning material to clean the pulleys.
(Battery Charging Alternator)
3. If necessary, install a new belt (9) to the pulley of
alternator (7) and the lower pulley. Ensure that the
belt is correctly installed. For a used belt (9)
ensure that the belt is installed with the temporary
Removal Procedure
marks in the correct direction.
4. Use a suitable tool to move alternator (7) in an
upward direction to set the belt tension. Refer to Accidental engine starting can cause injury or
Operation and Maintenance Manual, Alternator death to personnel working on the equipment.
and Fan Belts - Replace for the correct To avoid accidental engine starting, disconnect
information. the battery cable from the negative (−) battery ter-
5. Tighten self-locking nut and bolt (8) and Slacken disconnected battery cable end in order to pre-
self-locking nut and bolt (11) securely. vent contact with other metal surfaces which
UENR4544 205
NOTICE
component life.

2. Make temporary identification marks on the
harness assemblies that are connected to the
alternator. Disconnect the harness assemblies
from the alternator.
5. Remove alternator belt (11) from alternator (7).

Refer to Disassembly and Assembly, Alternator
Belt - Remove and Install for the correct
procedure.
6. Disconnect harness assembly (12) from alternator
(7).
7. Remove the self-locking nut and bolt (15) from
alternator (7) and bracket (14).
8. Support the weight of the alternator and remove
the self-locking nut and bolt (8) from alternator (7).
Remove the alternator from bracket (10).
3. Loosen captive bolt (2) and captive bolt (6) for remove bracket (10) and bracket (14).
upper guard (3). Remove the upper guard from the
alternator. a. Remove bolts (9) from bracket (10). Remove
the bracket from the tube assembly.
lower guard (5). Remove the lower guard from the b. Remove bolt (13) from bracket (14). Remove
alternator. the bracket from the back plate.
10. If necessary, follow Step 10.a through Step 10.c
to remove the pulley from the alternator.
206 UENR4544
NOTICE
component life.
1. Ensure all components of the alternator, brackets,

and pulley are free from wear or damage. Replace
2. If necessary, follow Step 2.b through Step 2.d to
install the pulley for the alternator.
a. Remove grub screws (16) from pulley (11).
a. Ensure the mating surfaces of the two halves

of pulley (11) are clean, dry, and free from
damage. Align the halves of the pulley. Lightly
lubricate grub screws (16) with clean engine
oil. Install the grub screws to the pulley finger
tight.

b. Install pulley (11) to the alternator.
c. Tighten grub screws (16). Tighten the grub

b. Lubricate one screw (16) with clean engine oil. screws alternately and tighten the grub screws
Install the grub screw into the jacking hole in evenly to a torque of 22 N·m (15 lb ft).
pulley (11). Tighten the grub screw until the
center of the pulley is released from the shaft d. Tap the outer half of pulley (11) with a soft
of the alternator. faced hammer to seat the two halves of the
pulley.
c. Remove pulley (11) from the shaft of the
alternator. Remove grub screw (16) from Note: Use a block of wood to prevent damage to
pulley (11) and separate the two halves of the the pulley.
pulley.
e. Again, tighten grub screws (16) to a torque of
22 N·m (15 lb ft).
UENR4544 207
Note: Ensure that the pulley is seated against the

shoulder on the shaft of the alternator.
9. Install lower guard (5) and tighten captive bolt (1)

Illustration 423 g06016775 and captive bolt (4) to a torque of 10 N·m
(89 lb in).
3. If necessary, follow Step through Step to install
bracket (10) and bracket (14). 10. Install upper guard (3) and tighten captive bolt (1)
a. Position bracket (14) onto the back plate. (89 lb in).
Install bolt (13) hand tight.
11. Turn the battery disconnect switch to the ON
b. Position bracket (10)onto the tube assembly. position.
Install bolts (9)to the bracket.
Note: After the engine has been run for the
c. Tighten bolts (9) to a torque of 40 N·m appropriate length of time, check the tightness of the
grub screws that secure the alternator pulley. Refer
(30 lb ft).
to Operation and Maintenance Manual, “Alternator
4. Install alternator (7) to bracket (10). Support the Pulley - Check.” for more information.
weight of the alternator and install bolt (8) and the
self-locking nut. i06511717
5. Install bolt (15) and the self-locking nut to Alternator - Remove and Install
alternator (7) and bracket (14).
6. Connect harness assembly (12) to alternator (7).
(Battery Charging Alternator
Tighten the terminal nuts. Refer to Specifications, Drive)
Alternator and Regulator for the correct torque
values.
7. Install alternator belt (11) to alternator (7). Refer to Removal Procedure
Disassembly and Assembly, Alternator Belt -
Remove and Install for the correct procedure. NOTICE
8. After tensioning of the alternator belt, tighten bolt
(13) to a torque of 47 N·m (35 lb ft). Contaminants may cause rapid wear and shortened
component life.
Securely tighten the self-locking nut and bolt (8)
and the self-locking nut and bolt (15).
208 UENR4544
NOTICE
and mandates.


lower guard (5). Remove the lower guard from the
alternator.
upper guard (3). Remove the upper guard from the
alternator.
4. Remove the alternator. Refer to Disassembly and
Assembly, “Alternator (Battery Charging
Alternator) - Remove and Install” for the correct
procedure.
UENR4544 209

5. Remove grub screws (14) from pulley (10).
9. Removal of bearing carrier (15) can be carried out
6. Lubricate one grub screw (14) with clean engine
without removal of the alternator guard.
oil. Install the grub screw into the jacking hole in
pulley (10). Tighten the grub screw until the center 10. If necessary, follow Step 10.a through Step 10.f to
of the pulley is released from the shaft. remove bearing carrier (15).
7. Remove pulley (10) and key (11) from the shaft of a. Remove nuts (16) from bearing carrier (15).
the engine water pump. Remove grub screw (14)
from the pulley and separate the two halves of the b. Remove bearing carrier (15) from the back
pulley. plate.
8. If necessary, follow Step 8.a through Step 8.b to c. Remove gasket (18) (not shown).
remove guard (7).
d. Use a suitable tool to remove seal (19) from
a. Remove bolt (13) and remove bracket (9) from bearing carrier (15).
the back plate.
e. If necessary, remove studs (17) from the back
b. Remove nut and bolt (8)(not shown) and bolts plate.
(12) (not shown). Remove guard (7).
f. If necessary, place bearing carrier (15) on a
suitable press and remove bearing (20) (not
shown) from the bearing carrier.
Table 74
Required Tools

A - 1
lock
12mm X 12mm Pulley Align-
B - 1
ment Bar
210 UENR4544
NOTICE
Keep all parts clean from contaminants. f. Lubricate seal (19) and bearing (20) (not
shown) with clean engine oil.
component life. g. Install bearing carrier (15) onto the back plate.
h. Install nuts (16) to bearing carrier (15). Tighten

1. Ensure that all components are free from wear or the nuts to a torque of 25 N·m (18 lb ft).
damaged.
2. The bearing carrier (15) can be installed without

removing the alternator guard.
3. If necessary, follow Step 3.a through Step 3.h to
install bearing carrier (15).
a. Check the water shaft for the damage or burrs.

If necessary clean-up the water pump shaft
with suitable tooling before installation of the
bearing carrier (15).
b. If necessary, place bearing carrier (15) on a

suitable press and install a new bearing (20)
(not shown) to the bearing carrier. Ensure that
the bearing is correctly seated into the bearing
carrier.
c. If necessary, apply Tooling (A) to the threads
of studs (17). Install the studs to the back plate
and tighten the studs securely.
d. Use a suitable tool to install a new seal (19) to

bearing carrier (15). Ensure that the seal is
correctly seated into the bearing carrier.
e. Position a new gasket (18) (not shown) onto

studs (17).
UENR4544 211

Illustration 431 g06016888 Alignment Tool (B) positioned between the pulley and
the guard

remove guard (7).
a. Position guard (7) onto back plate. Install nut

and bolt (8)(not shown) and bolts (12) (not
shown). Hand tighten the nut and bolt and the
bolts.
b. Tighten the nut and bolt (8)and bolts (12) to a
torque of 47 N·m (35 lb ft). Ensure guard (7) is
not strained as the bolts and the nuts and bolt
are tightened.
c. Position bracket (9) to the back plate and

install bolt (13) hand tight.
5. Install key (11) to the shaft. Ensure that the key is
correctly seated into the shaft.
6. Ensure the mating surface of the two halves of
pulley (10) are clean, dry, and free from damage.
Illustration 432 g06016916 Align the halves of the pulley. Lightly lubricate grub
screws (14) with clean engine oil. Install the grub
screws to the pulley finger tight.
7. Install pulley (10) to the shaft of the engine water
pump.
8. Install Tooling (B) between pulley (10) and guard
(7).
9. Tighten grub screws (14). Tighten the grub screws
alternately and tighten the grub screws evenly to a
10. Tap the outer half of pulley (10) with a soft faced
hammer to seat the two halves of the pulley.
212 UENR4544
11. Again, tighten grub screws (14) to a torque of 17. Switch ON battery charger (if installed) or the
22 N·m (15 lb ft). connect the mains supply and connect the
12. Remove Tooling (B).
13. Install the alternator. Refer to Disassembly and i06511715
Assembly, “Alternator (Battery Charging
Alternator) - Remove and Install” for the correct Electric Starting Motor -
procedure.
Remove and Install
14. After the engine has been run for the appropriate
length of time, check the tightness of the grub
screws that secure the pulley. Refer to Operation
and Maintenance Manual, “Alternator Pulley - Removal Procedure
Check.” and Disassembly and Assembly,
“Alternator (Battery Charging Alternator Drive) -
NOTICE
component life.

2. Place identification marks on all the harness
15. Install lower guard (5) and tighten captive bolt (2) assemblies that are connected to the solenoids
and captive bolt (6) to a torque of 10 N·m and to the electric starting motors.
(89 lb in).
16. Install upper guard (5) and tighten captive bolt (1)
(89 lb in).
UENR4544 213
3. Disconnect harness assembly (3) and harness 7. If necessary, remove the solenoid and the bracket
assembly (5) from electric starting motor (2). from the engine oil pan. Follow Step 1.a through
Step 7.c to remove the solenoid and the bracket
4. Disconnect harness assembly (4) from electric
from the engine oil pan.
starting motor (2).
5. Attach a suitable sling and a lifting device to the a. Disconnect harness assembly (6), harness
upper electric starting motor (2). The weight of the assembly(10) and harness assembly (11) from
electric starting motor is approximately 26 kg solenoid (12).
(57 lb).
b. Remove the nuts and bolts (9) and remove
6. Remove nuts (1). Use the lifting device to remove solenoid (12) from bracket (8).
electric starting motor (2) from the flywheel
housing. c. Remove bolts (7) and remove bracket (8) from
the engine oil pan.
NOTICE
component life.
214 UENR4544
1. If necessary, install the solenoid and the bracket to 2. Attach a suitable sling and a lifting device to the
the engine oil pan. Follow Step 1.a through Step 1. lower electric starting motor (2). The weight of the
c to install the solenoid and the bracket to the electric starting motor is approximately 26 kg
engine oil pan. (57 lb).
a. Position bracket (8) onto the engine oil pan. 3. Use the lifting device to install electric starting
Install bolts (7) and tighten the bolts to a motor (2) to the flywheel housing. Install nuts (1).
torque of 47 N·m (35 lb ft). Tighten the nuts to a torque of 85 N·m (60 lb ft).
4. Connect harness assembly (3) and harness
b. Position solenoid (12) onto bracket (8). Install
assembly (5) to electric starting motor (2). Tighten
the nuts and bolts (9) and tighten the bolts to a
nuts for the harness assemblies securely.
5. Connect harness assembly (4) to electric starting
c. Connect harness assembly (6), harness motor (2). Tighten nuts for the harness assembly
assembly (10) and harness assembly (11) to securely.
solenoid (12). Tighten nuts for the harness
assemblies securely. 6. Switch ON battery charger (if installed) or the
UENR4544 215
Index Section
Index
A Installation Procedure .................................... 190
Removal Procedure ....................................... 190
Air Cleaner - Remove and Install ..........................37 Crankshaft Main Bearings - Remove and Install... 184
Installation Procedure ......................................38 Installation Procedure .................................... 185
Removal Procedure .........................................37 Removal Procedure ....................................... 184
Air Lines - Remove and Install (Turbocharger Crankshaft Rear Seal - Remove and Install ......... 123
Compressor Outlet Tube Assemblies) .................53 Installation Procedure .................................... 123
Installation Procedure for Center Section of Tube Removal Procedure ....................................... 123
Assembly ......................................................59 Cylinder Head - Install ....................................... 155
Installation Procedure for Front Section of Tube Installation Procedure .................................... 155
Assembly ......................................................60 Cylinder Head - Remove.................................... 152
Installation Procedure for Rear Section of Tube Removal Procedure ....................................... 152
Assembly ......................................................57 Cylinder Liner - Install ........................................ 171
Removal Procedure for Center Section of Tube Installation Procedure .................................... 171
Assembly ......................................................55 Cylinder Liner - Remove .................................... 170
Removal Procedure for Front Section of Tube Removal Procedure ....................................... 170
Assembly ......................................................53
Removal Procedure for Rear Section of Tube
Assembly ......................................................56 D
Alternator - Remove and Install (Battery
Charging Alternator Drive)................................ 207 Disassembly and Assembly Section .......................4
Installation Procedure .................................... 209
Alternator - Remove and Install (Battery E
Charging Alternator) ........................................ 204 Electric Starting Motor - Remove and Install ........ 212
Installation Procedure .................................... 206 Installation Procedure .................................... 213
Removal Procedure ....................................... 204 Removal Procedure ....................................... 212
Alternator Belt - Remove and Install.................... 203 Engine Oil Cooler - Assemble...............................94
Installation Procedure .................................... 204 Assembly Procedure ........................................94
Removal Procedure ....................................... 203 Engine Oil Cooler - Disassemble ..........................93
Disassembly Procedure ...................................93
Engine Oil Cooler - Install ....................................95
B Installation Procedure ......................................95
Bearing Clearance - Check ................................ 191 Engine Oil Cooler - Remove.................................90
Measurement Procedure ................................ 191 Removal Procedure .........................................90
Boost Pressure Sensor - Remove and Install....... 199 Engine Oil Filter Base - Install ..............................88
Installation Procedure .................................... 200 Installation Procedure ......................................88
Removal Procedure ....................................... 199 Engine Oil Filter Base - Remove...........................86
Removal Procedure .........................................86
Engine Oil Pan - Install ...................................... 168
C Installation Procedure .................................... 168
Engine Oil Pan - Remove................................... 166
Camshaft - Install .............................................. 163 Removal Procedure ....................................... 166
Installation Procedure .................................... 163 Engine Oil Pressure Switch - Remove and
Camshaft - Remove .......................................... 162 Install ............................................................. 193
Removal Procedure ....................................... 162 Installation Procedure .................................... 194
Camshaft Bearings - Install ................................ 165 Removal Procedure ....................................... 193
Installation Procedure .................................... 165 Engine Oil Pressure Switch - Remove and
Camshaft Bearings - Remove ............................ 164 Install (Alternator Warning Lamp)...................... 194
Coolant Temperature Switch - Remove and Removal Procedure ....................................... 194
Install ............................................................. 192 Engine Oil Pump - Assemble.............................. 105
Installation Procedure .................................... 192 Assembly Procedure ...................................... 105
Removal Procedure ....................................... 192 Engine Oil Pump - Disassemble ......................... 104
Crankcase Breather - Remove and Install ........... 141 Disassembly Procedure ................................. 104
Installation Procedure .................................... 142 Engine Oil Pump - Install.................................... 107
Crankshaft - Install ............................................ 187 Engine Oil Pump - Remove ................................ 102
Installation Procedure .................................... 187 Removal Procedure ....................................... 102
Crankshaft - Remove......................................... 186 Engine Oil Relief Valve - Remove and Install
Removal Procedure ....................................... 186 (Engine Oil Cooler) .......................................... 100
Crankshaft Front Seal - Remove and Install......... 132 Installation Procedure .................................... 101
Installation Procedure .................................... 132 Removal Procedure ....................................... 100
Crankshaft Gear - Remove and Install ................ 190
216 UENR4544
Index Section
Engine Oil Relief Valve - Remove and Install Installation Procedure ......................................15
(Engine Oil Pressure Regulator) .........................98 Installation Procedure for Guard........................20
Installation Procedure ......................................98 Removal Procedure .........................................13
Engine Speed Sensor - Remove and Install
(Engine Speed for Governor Control) ................ 198 H
Installation Procedure .................................... 198 Housing (Front) - Install (Timing Case)................ 138
Engine Speed Sensor - Remove and Install Housing (Front) - Remove (Timing Case) ............ 137
(Overspeed Sensor) ........................................ 196 Removal Procedure ....................................... 137
Engine Support (Front) - Remove and Install I
(Back plate)..................................................... 117
Installation Procedure .................................... 118 Important Safety Information ..................................2
Removal Procedure ....................................... 117 Inlet and Exhaust Valve Guides - Remove and
Exhaust Elbow - Remove and Install.....................73 Install ...............................................................85
Installation Procedure ......................................74 Installation Procedure ......................................85
Removal Procedure .........................................73 Removal Procedure .........................................85
Exhaust Manifold - Remove and Install .................63 Inlet and Exhaust Valves - Remove and Install.......82
Installation Procedure ......................................67 Installation Procedure ......................................83
Removal Procedure .........................................63 Removal Procedure .........................................82
Inlet Manifold - Install...........................................79
Installation Procedure ......................................79
F Inlet Manifold - Remove .......................................76
Flywheel - Install ............................................... 121
Flywheel - Remove............................................ 119 L
Flywheel Housing - Remove and Install............... 124 Lifter Group - Assemble (Cam Followers)............ 160
Installation Procedure .................................... 125 Assembly Procedure ...................................... 160
Removal Procedure ....................................... 124 Lifter Group - Disassemble (Cam Followers) ....... 158
Fuel Injection Control Linkage - Install...................25 Disassembly Procedure ................................. 158
Installation of the Fuel Injection Control Linkage Lifter Group - Install (Cam Followers).................. 161
from the Crankcase ........................................25 Installation Procedure .................................... 161
Fuel Injection Control Linkage - Remove ...............20 Lifter Group - Remove (Cam Followers) .............. 158
Removal Procedure .........................................20 Removal Procedure ....................................... 158
Fuel Injector - Install ............................................31
Fuel Injector - Remove ........................................30 P
Removal Procedure .........................................30 Piston Cooling Jets - Remove and Install ............ 173
Fuel Injector Sleeve - Install .................................34 Installation Procedure .................................... 174
Installation Procedure ......................................34 Removal Procedure ....................................... 173
Fuel Injector Sleeve - Remove .............................33 Pistons and Connecting Rods - Assemble........... 178
Removal Procedure .........................................33 Assembly Procedure ...................................... 178
Fuel Manifold (Rail) - Remove and Install Pistons and Connecting Rods - Disassemble ...... 177
(Engine Oil and Fuel Rail) ....................................5 Disassembly Procedure ................................. 177
Installation Procedure ........................................7 Pistons and Connecting Rods - Install................. 181
Removal Procedure ...........................................5 Installation Procedure .................................... 181
Fuel Transfer Pump - Remove and Install (Lift Pistons and Connecting Rods - Remove ............. 175
Pump) ................................................................4 Removal Procedure ....................................... 175
Installation Procedure ........................................4
Removal Procedure ...........................................4
R
G Rocker Arm - Assemble ..................................... 149
Assembly Procedure ...................................... 149
Gear Group (Front) - Install ................................ 134 Rocker Arm - Disassemble................................. 148
Installation Procedure .................................... 134 Disassembly Procedure ................................. 148
Gear Group (Front) - Remove ............................ 133 Rocker Arm and Shaft - Install ............................ 151
Governor - Install (Electronic Control Unit) ............12 Rocker Arm and Shaft - Remove ........................ 147
Installation Procedure ......................................12 Removal Procedure ....................................... 147
Governor - Remove (Electronic Control Unit)......... 11
Removal Procedure ......................................... 11
Governor Actuator - Remove and Install................13 T
Adjustment and Set Up Procedure for a New
Governor Actuator Lever.................................19 Table of Contents ..................................................3
UENR4544 217
Index Section
Temperature Sensor (Exhaust) - Remove and

Install (Exhaust Temperature Thermocouples) ... 195
Turbocharger - Install ..........................................45
Installation Procedure For Inner and Outer
Turbocharger Connections..............................47
Installation Procedure For Inner Turbocharger ...49
Installation Procedure For Outer Turbocharger...51
Installation Procedure for Turbochargers Oil feed
and Drain Tube Assemblies ............................45
Turbocharger Orientation .................................48
Turbocharger - Remove.......................................40
Removal Procedure For Inner and Outer
Turbocharger Connections..............................42
Removal Procedure For Inner Turbocharger ......42
Removal Procedure For Outer Turbocharger .....41
Removal Procedure for Turbochargers Oil feed
and Drain Tube Assemblies ............................43
V
V-Belts - Remove and Install (Fan Drive Belts)..... 200
Valve Mechanism Cover - Remove and Install
(Rocker Box Cover) ......................................... 144
Valve Mechanism Cover Base - Remove and
Install (Rocker Box) ......................................... 145
Vibration Damper and Pulley - Remove and
Install (Twin Vibration Dampers) ....................... 127
W
Water Pump - Assemble .................................... 112
Assembly Procedure ...................................... 112
Water Pump - Disassemble................................ 111
Disassembly Procedure ................................. 111
Water Pump - Install .......................................... 113
Water Pump - Remove ...................................... 110
Water Temperature Regulator Housing -
Remove and Install (Thermostat Housing) ......... 114
©2016 Perkins Engines Company Limited
All Rights Reserved

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UENR4544 (en-us)

Disassembly and Assembly

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Valve Mechanism Cover - Remove and Install

Fuel Transfer Pump - Remove

1. Ensure that the gasket surfaces of the fuel lift

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

Fuel Manifold (Rail) - Remove

5. Remove the cap from tube assembly (3) and

5. Disconnect tube assembly (5), tube assembly (6),

10. Use a suitable tool to hold connection (17) and

3. Remove bolt (3) from clip (4).

h. Make temporary marks on bracket (26) and

i. Remove nuts and bolts (24) and remove

j. If necessary, repeat Step 12.h through Step

Tool Part Number Part Description Qty

Loctite 542 Thread and Nut

1. Ensure that all components for engine oil rail and

12. Follow Step 12.a through Step 12.j to

a. Remove connections (21) from engine oil rail

b. Remove sealing washers (20) (not shown)

c. Repeat Step 12.a through Step 12.b to

d. Remove connection (17) from engine oil rail

e. Remove sealing washers (20) (not shown).

f. Remove connection (10) and connection (13)

g. Remove sealing washer (23) (not shown) and

torque of 35 N·m (26 lb ft).

g. Install new sealing washers (20) (not shown)

h. Apply Tooling (A) to the threads of

i. If necessary, repeat Step 2.g through Step 2.k

j. Install a new seal washer (22) to connection

k. Apply Tooling (A) to the threads of connection

2. Follow Step 2.a through Step 2.k to disassembly

a. Position bracket (26) onto engine oil rail (1).

f. Install connection (10) and connection (13) to

7. Position clamps (15) onto tube assembly (11) and

11. Use a suitable tool to hold connections (21) and

6. Connect tube assembly (8) to connection (10).

18. Use a suitable tool to hold connection (17) and

23. Before starting the engine after either engine oil

2. Mark temporary marks on harness assembly (2),

1. Switch OFF battery charger (if installed) or the

5. Remove nuts (6) and nuts (11) from bracket (7)

a. Remove nuts and bolts (9) and nuts and bolts

c. If necessary, remove nuts (8) from rubber

1. Ensure that all components of the governor control

8. If necessary, follow Step 8.a through Step 8.c to

a. Remove screws (14) and remove cover (13)

b. Remove Allen head bolts and nuts (15) from

a. Position governor control unit (1) onto bracket

c. Tighten Allen head bolts and nuts (15) to a

d. Install cover (13) to governor control unit (1).

6. Connect Original Equipment Manufacture (OEM)

c. Tighten nuts and bolts (9) to a torque of Governor Actuator - Remove

Accidental engine starting can cause injury or

Removal of Governor Actuator

3. Disconnect harness assembly (3) from governor

2. Remove bolts (2) from guard (1). Remove the

Personal injury can result from being struck by

b. If necessary, remove studs (11) from

8. If necessary, remove self-locking nut and bolt (10)

a. Remove nut and bolt (17) from lever (14).