Kenr6232 00 PDF

KENR6232-00
August 2006
Disassembly and
Assembly
2506-15 Industrial Engine
MGA (Engine)
MGB (Engine)
MGD (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.
KENR6232 3
Table of Contents
Table of Contents Cylinder Head - Remove ...................................... 51

Cylinder Head - Install .......................................... 53
Camshaft - Remove .............................................. 56
Camshaft - Install .................................................. 58
Disassembly and Assembly Section Camshaft Gear - Remove and Install .................. 60
Camshaft Bearings - Remove ............................... 61
Fuel Priming Pump - Remove and Install ............ 4
Camshaft Bearings - Install ................................... 62
Fuel Filter Base - Remove ................................... 4
Engine Oil Pan - Remove and Install ................... 64
Fuel Filter Base - Disassemble ............................. 5
Cylinder Liner - Remove ....................................... 65
Fuel Filter Base - Assemble .................................. 6
Cylinder Liner - Install ........................................... 66
Fuel Filter Base - Install ....................................... 6
Piston Cooling Jets - Remove and Install ............. 66
Fuel Transfer Pump - Remove .............................. 7
Pistons and Connecting Rods - Remove .............. 67
Fuel Transfer Pump - Install .................................. 7
Pistons and Connecting Rods - Disassemble ....... 68
Electronic Unit Injector - Remove ......................... 8
Pistons and Connecting Rods - Assemble ........... 69
Electronic Unit Injector - Install ............................. 9
Pistons and Connecting Rods - Install .................. 70
Electronic Unit Injector Sleeve - Remove ............. 10
Connecting Rod Bearings - Remove (Connecting
Electronic Unit Injector Sleeve - Install ................. 11
rods in position) ................................................... 71
Turbocharger - Remove ........................................ 12
Connecting Rod Bearings - Install (Connecting rods
Turbocharger - Install ............................................ 13
in position) ........................................................... 71
Exhaust Manifold - Remove and Install ............... 14
Crankshaft Main Bearings - Remove .................... 73
Exhaust Elbow - Remove and Install ................... 15
Crankshaft Main Bearings - Install ........................ 74
Inlet and Exhaust Valve Springs - Remove and
Crankshaft - Remove ............................................ 75
Install ................................................................... 15
Crankshaft - Install ................................................ 77
Inlet and Exhaust Valves - Remove and Install .... 17
Bearing Clearance - Check ................................... 79
Inlet and Exhaust Valve Guides - Remove and
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 19
Install ................................................................... 80
Engine Oil Filter Base - Remove .......................... 20
Camshaft Position Sensor - Remove and Install .. 81
Engine Oil Filter Base - Disassemble ................... 21
Crankshaft Position Sensor - Remove and
Engine Oil Filter Base - Assemble ........................ 21
Install ................................................................... 82
Engine Oil Filter Base - Install .............................. 22
Coolant Temperature Sensor - Remove and
Engine Oil Cooler - Remove ................................. 23
Install ................................................................... 83
Engine Oil Cooler - Install ..................................... 23
Engine Oil Pressure Sensor - Remove and Install
Engine Oil Pump - Remove .................................. 24
............................................................................. 84
Engine Oil Pump - Disassemble ........................... 24
Fuel Temperature Sensor - Remove and Install ... 85
Engine Oil Pump - Assemble ................................ 25
Inlet Manifold Temperature Sensor - Remove and
Engine Oil Pump - Install ...................................... 26
Install ................................................................... 86
Water Pump - Remove ......................................... 27
Inlet Manifold Pressure Sensor - Remove and
Water Pump - Install ............................................. 28
Install ................................................................... 87
Water Temperature Regulator Housing - Remove and
Belt Tightener - Remove ....................................... 88
Install .................................................................. 28
Belt Tightener - Install ........................................... 89
Engine Support (Front) - Remove and Install ....... 30
Fan - Remove and Install ..................................... 89
Flywheel - Remove ............................................... 31
Fan Drive - Remove ............................................. 90
Flywheel - Install ................................................... 32
Fan Drive - Install .................................................. 91
Crankshaft Rear Seal - Remove ........................... 33
Pump Drive - Remove (Transfer pump) ................ 91
Crankshaft Rear Seal - Install ............................... 34
Pump Drive - Disassemble (Transfer pump) ......... 92
Flywheel Housing - Remove and Install .............. 34
Pump Drive - Assemble (Transfer pump) ............. 93
Vibration Damper and Pulley - Remove and Install
Pump Drive - Install (Transfer pump) .................... 93
............................................................................. 36
Electronic Control Module - Remove and Install ... 94
Crankshaft Front Seal - Remove .......................... 38
Alternator - Remove and Install ........................... 95
Crankshaft Front Seal - Install .............................. 39
Electric Starting Motor - Remove and Install ....... 96
Front Cover - Remove .......................................... 40
Front Cover - Install .............................................. 41
Gear Group (Front) - Remove .............................. 41 Index Section
Gear Group (Front) - Install .................................. 43
Housing (Front) - Remove .................................... 45 Index ..................................................................... 97
Housing (Front) - Install ........................................ 46
Crankcase Breather - Remove and Install (Open
Breather) ............................................................. 47
Valve Mechanism Cover - Remove and Install ..... 48
Rocker Arm and Shaft - Remove .......................... 49
Rocker Arm - Disassemble ................................... 49
Rocker Arm - Assemble ........................................ 50
Rocker Arm and Shaft - Install .............................. 51
4 KENR6232
Disassembly and Assembly Section
Disassembly and Assembly Installation Procedure

Section NOTICE
Keep all parts clean from contaminants.
i02554756
Contaminants may cause rapid wear and shortened
Fuel Priming Pump - Remove component life.
and Install
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01279497
Dispose of all fluids according to local regulations and Illustration 2
mandates.
1. Position a new joint (3) on fuel filter base (4).
NOTICE Note: Ensure correct orientation of the joint.
2. Position the fuel priming pump assembly (1) on
Contaminants may cause rapid wear and shortened the fuel filter base and install bolts (2). Tighten the
component life. 1/4" bolt to a torque of 12 N·m (105 lb in). Tighten
the 5/16" bolt to a torque of 25 N·m (221 lb in).
1. Turn the fuel supply to the “OFF” position.
3. Turn the fuel supply to the “ON” position.
4. Remove the air from the system. Refer to Systems

Operation, Testing and Adjusting, “Fuel System -
Prime”.
i02554755
Fuel Filter Base - Remove
Removal Procedure
Illustration 1
g01279497 NOTICE
2. Remove bolts (2). Remove fuel priming pump during performance of inspection, maintenance, test-
assembly (1) from fuel filter base (4). ing, adjusting and repair of the product. Be prepared to
3. Remove joint (3) from the fuel priming pump ing any compartment or disassembling any compo-
assembly and the fuel filter base. nent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
KENR6232 5
i02554753
NOTICE
Fuel Filter Base - Disassemble
component life.
Disassembly Procedure
1. Turn the fuel supply to the “OFF” position. Start By:
a. Remove the fuel filter base. Refer to Disassembly

and Assembly, “Fuel Filter Base - Remove”.
NOTICE

component life.
g01279811
Illustration 3
2. Place a suitable container below the fuel filter

base in order to drain the fuel from the fuel filter g01279898
assemblies (10) and (12). Illustration 4
3. Remove plugs (9) and (11). Allow the fuel to drain. 1. Remove fuel priming pump (4) from fuel filter
base assembly (1). Refer to Disassembly and
4. Disconnect harness assembly (1) from fuel Assembly, “Fuel Priming Pump - Remove and
temperature sensor (2). Install”.
Note: In order to disconnect the harness assembly, 2. Remove fuel temperature sensor (2) from fuel
slide the locking tab into the unlocked position. filter base assembly (1). Refer to Disassembly and
Assembly, “Fuel Temperature Sensor - Remove
5. Disconnect hose assembly (3). Disconnect hose and Install”.
assembly (5). Disconnect hose assemblies (7)
and (8). Plug the open hose assemblies. 3. Remove fuel bypass valve (6) from fuel filter base
assembly (1). Remove the O-ring seals from the
6. Use a suitable tool with a 1/2" square drive fuel bypass valve.
in order to remove fuel filter assemblies (10)
and (12). Remove the O-ring seals. Remove 4. Remove fuel check valve (10) from fuel filter base
the fuel filter elements. Refer to Operation and assembly (1). Remove the O-ring seals from the
Maintenance Manual, “Fuel Filter - Replace” for fuel check valve.
more information.
5. Remove connections (3), (5), (7) and (8) from fuel
7. Remove bolts (4). Remove fuel filter base (6). filter base assembly (1). Remove the O-ring seals
from the connections.
6. Remove plugs (9), (11) and (12) from fuel filter

base assembly (1). Remove the O-ring seals from
the plugs.
6 KENR6232
i02554752 6. Install fuel temperature sensor (2) to fuel filter

base assembly (1). Refer to Disassembly and
Fuel Filter Base - Assemble Assembly, “Fuel Temperature Sensor - Remove
and Install”.
7. Install fuel priming pump (4) to fuel filter

Assembly Procedure base assembly (1). Refer to Disassembly and
Assembly, “Fuel Priming Pump - Remove and
Install”.
NOTICE
Keep all parts clean from contaminants. End By:
Contaminants may cause rapid wear and shortened a. Install the fuel filter base. Refer to Disassembly
component life. and Assembly, “Fuel Filter Base - Install”.
1. Ensure that the filter base is clean and free from i02554754
damage. If necessary, replace the filter base.
Fuel Filter Base - Install
Installation Procedure
NOTICE

component life.
g01279898
Illustration 5
2. Install new O-ring seals to plugs (9), (11) and (12).

Install the plugs to fuel filter base assembly (1).
Tighten plug (9) to a torque of 41 N·m (30 lb ft).
Tighten plugs (11) and (12) to a torque of 15 N·m
(11 lb ft).
3. Install new O-ring seals to connections (3), (5), (7)

and (8). Install the connections to fuel filter base
assembly (1). Tighten connections (3), (5) and (7)
to a torque of 15 N·m (11 lb ft). Tighten connection
(8) to a torque of 41 N·m (30 lb ft).
Note: Ensure correct orientation of the connections.
4. Install new O-ring seals to fuel bypass valve (6).

Install the fuel bypass valve to fuel filter base
assembly (1). Tighten fuel bypass valve (6) to a g01279811
torque of 35 N·m (26 lb ft). Illustration 6
5. Install new O-ring seals to fuel check valve (10). 1. Position fuel filter base (6) and install bolts (4).
Install the fuel check valve in fuel filter base Tighten the bolts to a torque of 47 N·m (35 lb ft).
assembly (1). Tighten the fuel check valve to a
torque of 35 N·m (26 lb ft). 2. Install new O-ring seals and new fuel filter
elements to fuel filter assemblies (10) and (12).
Use a suitable tool with a 1/2" square drive in
order to install the fuel filter assemblies.
KENR6232 7
Install new O-ring seals to plugs (9) and (11).

Install the plugs to fuel filter assemblies (10) and
(12).
Refer to Operation and Maintenance Manual,

“Fuel Filter - Replace” for more information.
3. Connect hose assemblies (3), (5), (7) and (8).
4. Connect harness assembly (1) to fuel temperature

sensor (2). Slide the locking tab into the locked
position.

g01280901
6. Remove the air from the system. Refer to Systems Illustration 7
Operation, Testing and Adjusting, “Fuel System -
Prime”. 3. Disconnect hose assemblies (2) and (3) from fuel
transfer pump (1). Plug the open hose assemblies.
i02554761 4. Remove bolts (4) and remove fuel transfer pump

(1).
Fuel Transfer Pump - Remove
5. Remove the O-ring seal from fuel transfer pump
(1).
Removal Procedure i02554849
NOTICE Fuel Transfer Pump - Install

NOTICE
Dispose of all fluids according to local regulations and Keep all parts clean from contaminants.
mandates.
component life.
NOTICE
1. Ensure that the fuel transfer pump is clean and
Contaminants may cause rapid wear and shortened free from damage.
component life.
1. Turn the fuel supply to the “OFF” position.
2. Place a suitable container below the fuel transfer

pump in order to catch any fuel that might be
spilled.
g01280943
Illustration 8
2. Lubricate a new O-ring seal with clean engine oil.

Install the O-ring seal to fuel transfer pump (1).
8 KENR6232
3. Position fuel transfer pump (1) on pump drive (5).
Note: Ensure that the splines on the shaft of the fuel

transfer pump are correctly engaged into the pump
drive.
4. Install bolts (4). Tighten the bolts to a torque of

47 N·m (35 lb ft).
5. Remove the plugs from the hose assemblies.

Connect hose assemblies (2) and (3) to fuel
transfer pump (1).

g01150587
7. Remove the air from the fuel system. Refer to Illustration 9
Systems Operation, Testing and Adjusting, “Fuel
System - Prime”. 2. Disconnect harness assembly (1) from electronic
unit injector (2).
i02554720 3. Remove valve bridges (3).

Electronic Unit Injector -
NOTICE
Remove If the injector hold down bolt is loose during the re-
moval procedure, inspect the injector bore for wear
and debris. Replace the clamp and spacer.
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 27610288 Pry Bar 1
Start By:
a. Remove the rocker arms and the rocker arm shaft.

Refer to Disassembly and Assembly, “Rocker Arm
and Shaft - Remove”.
g01284035
Illustration 10
NOTICE
Keep all parts clean from contaminants. 4. Remove bolts (8) and washers (9). Remove
harness assembly (1) and support bracket (7) as
Contaminants may cause rapid wear and shortened a unit.
component life.
5. Remove bolt (4) and spacer (5).
1. Turn the fuel supply to the OFF position.
6. Place an identification mark on electronic unit
injector (2) for installation purposes. Each
electronic unit injector must be reinstalled in the
original location in the cylinder head.
KENR6232 9
i02554719
Electronic Unit Injector - Install
Table 2
Required Tools
Tool Part Part Description Qty
Number
GE50028 Vacuum Pump 1
g01073439
Illustration 11 GE50046 Fluid Sampling Bottle 1
B
7. Use Tooling (A) to pry beneath the base and free Tube
GE50030 1
7.9 mm (0.31 inch) OD
electronic unit injector (2).
C - Large Bore Brush 1
8. Remove electronic unit injector (2) and clamp (6)
from the cylinder head. Surface Reconditioning
D 27610308 1
Pad
E 27610296 Torque Wrench 1
NOTICE

component life.
1. Use Tooling (D) to clean the carbon deposit from

the inside of the electronic unit injector sleeve.
2. Use Tooling (B) to remove the fuel and oil from

g01284341 the cylinder. Evacuate as much fuel and oil as
Illustration 12
possible from the cylinder before installing the
electronic unit injector. Several evacuations may
9. Remove O-ring seals (11) and (12) from electronic be necessary.
unit injector (2).
g01284074
Illustration 13
3. Ensure that seat area (X) on the electronic unit

injector is clean and free carbon.
4. Install new O-ring seals (11) and (12) on the

electronic unit injector. Lubricate the O-ring seals
with clean engine oil.
10 KENR6232
5. Install a new O-ring seal (13) on the electronic unit Note: Ensure that used valve bridges are reinstalled
injector. in the original location and the original orientation.
Do not interchange the location or the orientation of
Note: O-ring seal (13) should be installed dry. used valve bridges.
NOTICE 11. Install the rocker arms and the rocker arm shaft.
If a replacement electronic unit injector is installed, the Refer to Disassembly and Assembly, “Rocker Arm
calibration code must be programmed into the elec- and Shaft - Install”.
tronic control module. Refer to Troubleshooting Guide,
“Injector Trim File” for more information. 12. Turn the fuel supply to the “ON” position.
13. Remove the air from the fuel system. Refer to

Systems Operation, Testing and Adjusting, “Fuel
System - Prime”.
i02554722
Electronic Unit Injector Sleeve

- Remove
Removal Procedure
g01150587 Table 3
Illustration 14
Required Tools
6. Install clamp (6) to electronic unit injector (2). Tool Part Number Part Description Qty
Install electronic unit injector (2) into the original
location in the cylinder head. A GE50021 Injector Sleeve Tool 1
7. Install spacer (5) and bolt (4). Tighten bolt (4) to a Start By:
torque of 55 N·m (41 lb ft).
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
NOTICE

component life.
1. Drain the coolant from the engine. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
g01284035
Illustration 15
8. Install harness assembly (1) and support bracket

(7) as a unit. Install bolts (8) and washers (9).
Tighten bolts (8) to a torque of 105 N·m (77 lb ft).
9. Connect harness assembly (1) to electronic unit

injector (2). Use Tooling (E) to tighten the nuts to a
torque of 2.5 N·m (22 lb in).
10. Install bridge assemblies (3) in the respective

locations.
KENR6232 11
NOTICE
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and
sealant debris.
g01076133
Illustration 16
2. Install Tooling (A) in electronic unit injector sleeve

(1).
3. Tighten the nut on Tooling (A) until the electronic g01043165

unit injector sleeve is pulled free of the cylinder Illustration 17
head.
2. Install new O-ring seals (2) and (3) to electronic
4. Remove O-ring seals (2) and O-ring seal (3) from unit injector sleeve (1).
electronic unit injector sleeve (1).
Note: Do not apply Tooling (C) to the cylinder head
surfaces. Apply Tooling (C) to the electronic unit
i02554721 injector sleeve only.
Electronic Unit Injector Sleeve 3. Apply a small continuous bead of Tooling (C) to
- Install surface (X) of electronic unit injector sleeve (1).
4. Lubricate O-ring seals (2) with clean engine oil.
5. Position Tooling (A) and the electronic unit injector

Installation Procedure sleeve in the cylinder head. Use care not to
damage the O-ring seals on the electronic unit
Table 4
injector sleeve.
Required Tools
6. Use Tooling (A) to install electronic unit injector
sleeve (1) in the cylinder head.
A GE50021 Injector Sleeve Tool 1
Note: Ensure that the electronic unit injector sleeve
GE50023 Tapered Brush 1
is properly seated in the cylinder head.
B GE50024 Small Bore Brush 1
7. Remove Tooling (A). Use a clean towel and
GE50022 End Brush 1
remove excess Tooling (C).
C CV60893 Retaining Compound 1
8. Fill the cooling system with coolant. Refer to
Operation and Maintenance, “Refill Capacities” for
NOTICE the cooling system capacity.
End By:
component life. a. Install the electronic unit injectors. Refer to
1. Use Tooling (B) to clean the bore in the cylinder Injector - Install”.
head for the electronic unit injector sleeve.
12 KENR6232
i02554785
Turbocharger - Remove
Removal Procedure
Start By:
a. Remove the exhaust elbow. Refer to Disassembly

and Assembly, “Exhaust Elbow - Remove and
Install”.
NOTICE

mandates.
NOTICE

component life.
1. Disconnect the air hoses for the turbocharger inlet

and for the turbocharger outlet.
g01283022
Illustration 18
2. Follow Steps 2.a through 2.c in order to remove

the tube assembly (7) for the oil feed.
a. Remove tube clamp (9) that secures tube

assembly (7) to tube assembly (8). Note the
position of the clamp.
b. Disconnect tube assembly (7) from the engine

oil filter base.
c. Remove bolts (3). Remove tube assembly (7)

and joint (2) from turbocharger (1).
3. Follow Steps 3 through 3.c in order to remove the

tube assembly (8) for the oil drain.
a. Remove bolts (6).
KENR6232 13
b. Remove tube assembly (8) and joint (5).
c. Remove O-ring seal (10) from tube assembly

(8).
4. Attach a suitable lifting device to turbocharger (1).

The weight of the turbocharger is approximately
30 kg (66 lb).
5. Remove the fasteners for the turbocharger. Use

the lifting device to remove turbocharger (1) from
the exhaust manifold. Remove gasket (4).
i02554784
Turbocharger - Install
Table 5
Required Tools
Tool Part Part Description Qty
Number
A CV60889 Anti-Seize Compound 1
NOTICE

component life.
g01283022
Illustration 19
1. Clean the mating surfaces of the exhaust manifold.

Position a new gasket (4) on the exhaust manifold.
2. Attach a suitable lifting device to turbocharger

(1). The weight of turbocharger is approximately
30 kg (66 lb). Use the lifting device to install
turbocharger (1) onto the exhaust manifold.
3. Apply Tooling (A) to the threads of the exhaust

manifold bolts. Install the bolts and install locknuts
finger tight.
4. Install a new O-ring seal (10) to tube assembly

(8). Install tube assembly (7) and new joint (5).
Install bolts (6) finger tight.
5. Install tube assembly (7) and a new joint (2).

Install bolts (3) finger tight. Connect the lower end
of tube assembly (7) to the engine oil filter base.
14 KENR6232
6. Install tube clamp (9) to tube assembly (7) to tube 5. If necessary, remove the taperlock studs from the
assembly (8). cylinder head.
Note: Ensure that the clamp is installed in the correct

position.
Table 6
7. Tighten the fasteners for the turbocharger to a
torque of 55 N·m (41 lb ft). Required Tools
8. Tighten the bolts for tube assemblies (7) and (8)
A CV60889 Anti-Seize Compound -
to a torque of 47 N·m (35 lb ft).
9. Connect the air hoses for the turbocharger inlet NOTICE

and for the turbocharger outlet. Keep all parts clean from contaminants.
i02554739 Contaminants may cause rapid wear and shortened

component life.
Exhaust Manifold - Remove
and Install 1. Install the taperlock studs in the cylinder head and
tighten to a torque of 35 N·m (26 lb ft).
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.
b. Remove the water temperature regulator housing.

Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install”.
g01283599
Illustration 21
2. Assemble exhaust manifolds (4), (5) and (6).
3. Install the exhaust manifold gaskets onto the

taperlock studs.
4. Install the assembly of the exhaust manifolds on

the taperlock studs.
Note: Ensure that the holes in exhaust manifolds are

centralized with the taperlock studs.
Illustration 20
g01283599 5. Apply Tooling (A) to the threads of the taperlock
studs. Install spacers (1), washers (2) and
1. Remove locknuts (3), washers (2) and spacers (1). locknuts (3).
2. Remove exhaust manifolds (4), (5) and (6).
Note: Remove manifolds as one assembly.
3. Remove the exhaust manifold gaskets.
4. Remove exhaust manifolds (4) and (6) from

exhaust manifold (5). Illustration 22
g01100255
KENR6232 15
6. Tighten the locknuts in a numerical sequence that Installation Procedures

is shown in Illustration 22. Tighten the locknuts to
a torque of 38 N·m (28 lb ft). NOTICE
End By:
a. Install the water temperature regulator housing. component life.
Install”.
b. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.
i02554738
Exhaust Elbow - Remove and

Install
Removal Procedure
NOTICE

component life. g01296103
Illustration 24
1. Thoroughly clean the exhaust elbow and the outlet

of the turbocharger. Inspect the components for
wear or damage. Replace any components that
are worn or damaged.
2. Position clamp (1) and install the exhaust elbow

to the turbocharger. Ensure correct orientation of
the band clamp.
3. Tighten the allen head bolt to a torque of 13.5 N·m

(10 lb ft).
i02554768
Inlet and Exhaust Valve

Springs - Remove and Install
Illustration 23
g01296103
Removal Procedure
1. Use an allen wrench in order to loosen clamp (1) Table 7
that secures the exhaust elbow. Required Tools
2. Remove the exhaust elbow and the clamp from Tool Part Number Part Description Qty
the turbocharger. A CH11148 Engine Turning Tool 1
B GE50026 Valve Spring Compressor 1
16 KENR6232
Start By:
a. Remove the electronic unit injectors. Refer to

NOTICE

component life.
Note: The following procedure should be adopted in

order to remove the valve springs when the cylinder
head is installed to the engine. Refer to Disassembly
and Assembly Manual, “Inlet and Exhaust Valves -
Remove and Install” for the procedure to remove the
valve springs from a cylinder head that has been
removed from the engine.
1. Use Tooling (A) to position the appropriate piston Illustration 26

g01284821
at the top center position before the valve spring
is removed.
Note: Failure to ensure that the piston is at the top

center position may allow the valve to drop into the Personal injury can result from being struck by
cylinder bore. parts propelled by a released spring force.
Make sure to wear all necessary protective equip-

NOTICE ment.
Do not turn the crankshaft while the valve springs are
removed. Follow the recommended procedure and use all
recommended tooling to release the spring force.
Note: Valve springs must be replaced in pairs for the
inlet valves or the exhaust valves of each cylinder. If 2. Install Tooling (B) in the electronic unit injector
all valve springs require replacement the procedure sleeve. Secure Tooling (B) with unit injector clamp
can be carried out on two cylinders at the same time. (1).
The procedure can be carried out on the following
pairs of cylinders. 1 with 6, 2 with 5, and 3 with 4. 3. Tighten the nut until valve keepers (3) are loose
Ensure that all of the valve springs are installed on valves (2).
before changing from one pair of cylinders to another
pair of cylinders. 4. Remove valve keepers (3).
5. Loosen the nut in order to release the pressure

on Tooling (B). Remove unit injector clamp (1).
Carefully remove Tooling (B).
6. Remove valve rotators (4).
7. Remove outer valve springs (6) and inner valve

g01284804
Illustration 25 springs (5).
8. Remove washers (7) from the valve guide.
KENR6232 17
Table 8
The valve spring keepers can be thrown from
Required Tools the valve when the valve spring compressor is
Tool Part Number Part Description Qty released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
B GE50026 Valve Spring Compressor 1 prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
NOTICE
6. Use Tooling (B) to compress the valve springs.
Contaminants may cause rapid wear and shortened Install valve keepers (3).
component life.
7. Loosen the nut in order to release the pressure
on Tooling (B). Remove unit injector clamp (1).
1. Inspect the valve springs for damage and for the
Carefully remove Tooling (B).
correct length. Refer to Specifications Manual,
“Cylinder Head Valves ”.
8. Lightly strike the top of the valve with a soft faced
hammer in order to ensure that valve keepers (2)
2. Lubricate the valve stems with clean engine oil.
are properly installed.
End By:
a. Install the electronic unit injectors. Refer to

Injector - Install”.
i02554769
Inlet and Exhaust Valves -

Remove and Install
Removal Procedure
Table 9
Required Tools
g01284821
Illustration 27
- Valve Spring
A 1
Compressor
Improper assembly of parts that are spring loaded Start By:

can cause bodily injury.
a. Remove the cylinder head. Refer to Disassembly
To prevent possible injury, follow the established and Assembly, “Cylinder Head - Remove”.
assembly procedure and wear protective equip-
ment. NOTICE
3. Install washers (7).
component life.
4. Install inner valve springs (5) and outer valve
springs (6).
5. Position valve rotators (4) on the valve springs.
18 KENR6232
Table 10
Required Tools
- Valve Spring
A 1
Compressor
B GE50027 Seal Installer 1
NOTICE

component life.
1. Inspect the valve springs for damage and for the

correct length. Refer to Specifications Manual,
“Cylinder Head Valves ”.
Note: Valve springs must be replaced in pairs for the

inlet valve or the exhaust valve of each cylinder.
2. Inspect the valves. Refer to Specifications,

“Cylinder Head Valves” for additional information
on the inlet and exhaust valves.
g01015263
Illustration 28
3. Use Tooling (B) in order to install new valve stem
seals onto the valve guides.
Personal injury can result from being struck by Note: The outer face of the valve guide must be
parts propelled by a released spring force. clean and dry before installing the valve stem seal.
Make sure to wear all necessary protective equip- 4. Lubricate the valves with clean engine oil. Install
ment. the valves in the cylinder head.
Follow the recommended procedure and use all

1. Install Tooling (A) and compress the valve springs.

Remove valve keepers (2) from valve (1).
2. Carefully remove Tooling (A) from valve (1).
3. Remove valve rotator (3).
4. Remove outer valve spring (5) and inner valve

spring (4) from valve (1).
5. Remove washer (6) and valve (1) from the valve

guide.
6. Remove the valve stem seal.
KENR6232 19
9. Carefully remove Tooling (A). Lightly strike the top

of the valve with a soft faced hammer in order
to ensure that valve keepers (2) are properly
installed.
End By:
a. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.
i02554766
Inlet and Exhaust Valve Guides

- Remove and Install
Removal Procedure
Table 11
Required Tools
A GE50043 Valve Guide Tool 1
g01015263
Start By:
Illustration 29
a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.
Improper assembly of parts that are spring loaded
can cause bodily injury. NOTICE
To prevent possible injury, follow the established
assembly procedure and wear protective equip- Contaminants may cause rapid wear and shortened
ment. component life.
5. Install washer (6).
6. Install inner valve spring (4) and outer valve spring

(5).
7. Position valve rotator (3) on the valve springs.
8. Use Tooling (A) to compress valve springs. Install

valve keepers (2) .
The valve spring keepers can be thrown from

the valve when the valve spring compressor is Illustration 30
g01289154
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help 1. Use Tooling (A) and a hammer to remove valve
prevent personal injury, keep away from the front guide (1) from the cylinder head.
of the valve spring keepers and valve springs
during the installation of the valves.
20 KENR6232
Installation Procedure i02554729
Table 12 Engine Oil Filter Base -

Required Tools Remove
A GE50043 Valve Guide Tool 1
B GE50044 Valve Guide Sleeve 1 Removal Procedure
Start By:
NOTICE
Keep all parts clean from contaminants. a. Remove the oil cooler. Refer to Disassembly and
Assembly, “Engine Oil Cooler - Remove”.
component life.
NOTICE

mandates.
NOTICE

g01289167
Illustration 31 component life.
1. Lubricate the bores for the valve guides with clean

engine oil.
2. Install valve guide (1) in the cylinder head with

Tooling (A) and Tooling (B).
Note: Tooling (B) must be used in order to install the

valve guide to the correct height.
Height to top of valve guide from cylinder head

surface ..... 35.00 ± 0.50 mm (1.378 ± 0.020 inch)
Note: For more information, refer to Specifications,

“Cylinder Head Valves”.
End By:
a. Install the inlet and exhaust valves. Refer to

Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.
g01282258
Illustration 32
1. Use a suitable tool with a 1/2" square drive in

order to remove engine oil filter (5). Remove the
O-ring seal. Remove the filter element. Refer to
Operation and Maintenance Manual, “Engine Oil
- Change” for more information.
KENR6232 21
2. Disconnect tube assembly (1).
3. Remove bolts (2) and bolts (4).
4. Remove engine oil filter base (3). Remove the

O-ring seals from the engine oil filter base.
i02554727
Engine Oil Filter Base -

Disassemble
Start By:
a. Remove the engine oil filter base. Refer to

Disassembly and Assembly, “Engine Oil Filter
g01282540
Base - Remove”. Illustration 33
NOTICE 1. Remove bolts (3). Remove elbow (1) from engine

Keep all parts clean from contaminants. oil filter base (2). Remove the O-ring seals from
the elbow.
component life. 2. Remove plug (5). Remove the O-ring seal from
plug (5).
3. Remove spring (7).
Personal injury can result from being struck by 4. Remove plunger (6).
parts propelled by a released spring force.
5. If necessary, remove oil sampling valve (4) from
Make sure to wear all necessary protective equip- the engine oil filter base. remove the O-ring seal
ment. from the oil sampling valve.
Follow the recommended procedure and use all i02554726

Engine Oil Filter Base -
Assemble
Assembly Procedure
NOTICE

component life.
22 KENR6232
i02554728
Engine Oil Filter Base - Install


assembly procedure and wear protective equip- Installation Procedure
ment.
NOTICE

component life.
g01282540
Illustration 34
1. Inspect the components for wear or damage.

Replace any components that are worn or
damaged.
g01282258
Illustration 35
2. Lubricate plunger (6) and spring (7) with clean
engine oil. Install the plunger and the spring into 1. Install new O-ring seals to engine oil filter base (3).
engine oil filter base (2).
2. Position engine oil filter base (3) on the engine
3. Install a new O-ring seal to plug (5). Install plug (5) and install bolts (2) and bolts (4). Tighten the bolts
to engine oil filter base (2). Tighten plug (5) to a to a torque of 47 N·m (35 lb ft).
3. Connect tube assembly (1).
4. Install new O-ring seals to elbow (1). Position
elbow (1) on the engine oil filter base and install 4. Install the oil cooler. Refer to Disassembly and
bolts (3). Assembly, “Engine Oil Cooler - Install”.
5. If necessary, install a new O-ring seal to oil 5. Install a new O-ring seal to engine oil filter (5).
sampling valve (4). Install oil sampling valve (4) to Install engine oil filter (5) to engine oil filter base
engine oil filter base (2). Tighten the oil sampling (3). Refer to Operation and Maintenance Manual,
valve to a torque of 24 N·m (18 lb ft). “Engine Oil - Change” for more information.
End By:
a. Install the engine oil filter base. Refer to

Disassembly and Assembly, “Engine Oil Filter
Base - Install”.
KENR6232 23
i02554725 i02554723
Engine Oil Cooler - Remove Engine Oil Cooler - Install
Removal Procedure Installation Procedure

Table 13
NOTICE
Care must be taken to ensure that fluids are contained Required Tools
Part
ing, adjusting and repair of the product. Be prepared to Tool Number Part Description Qty
ing any compartment or disassembling any compo- A 21820221
POWERPART -
nent containing fluids. Rubber Grease

NOTICE
mandates.
1. Drain the coolant from the cooling system into Contaminants may cause rapid wear and shortened
a suitable container for storage or for disposal. component life.
“Cooling System Coolant - Change”.
g01282186
Illustration 37
g01282186
Illustration 36
1. Install a new O-ring seal (10) to oil cooler bonnet
(5). Apply Tooling (A) to the O-ring seal. Install
2. Remove bolts (1). Remove outlet bonnet (3) from
joint (6) to oil cooler bonnet (5). Position the oil
the cylinder block and from the engine oil cooler.
cooler bonnet on the water pump and install bolts
Remove joint (2) and O-ring seal (7) from the
(11). Tighten the bolts finger tight.
outlet bonnet.
2. Install two new O-ring seals (9) to the engine oil
3. Remove bolts (8). Rotate core assembly (4) and
filter base.
slide the core assembly toward the rear of the
engine in order to remove the core assembly from
3. Slide core assembly (4) toward the front of the
the engine oil filter base. Remove O-ring seals (9)
engine. Rotate the core assembly into position.
from the engine oil filter base.
Install bolts (8). Tighten the bolts finger tight.
4. Remove bolts (11). Remove oil cooler bonnet (5)
4. Install a new O-ring seal (7) to outlet bonnet (3).
from the water pump. Remove joint (6) and O-ring
Apply Tooling (A) to the O-ring seal. Install joint (2)
seal (10) from the oil cooler bonnet.
to outlet bonnet (3). Position outlet bonnet (3) on
the core assembly and install bolts (1). Tighten
the bolts finger tight.
5. Tighten bolts (8), (1) and (11) to a torque of

47 N·m (35 lb ft).
24 KENR6232
6. Fill the cooling system. Refer to Operation and 2. Remove the fasteners and remove the assembly
Maintenance Manual, “Cooling System Coolant of the suction pipe (2). Remove the O-ring seal
- Change”. from the tube assembly.
7. Check the level of the engine lubricating oil. Refer 3. Remove bolts (5) and remove engine oil pump (1)
to Operation and Maintenance Manual, “Engine from the cylinder block.
Oil Level - Check”.
4. If necessary, remove bolts (4) and remove
underframe assembly (3).
i02554736
Engine Oil Pump - Remove i02554733
Engine Oil Pump - Disassemble

Removal Procedure
Start By: Disassembly Procedure
a. Remove the engine oil pan. Refer to Disassembly Table 14
and Assembly, “Engine Oil Pan - Remove and Required Tools
Install”.
NOTICE A - Puller (Three Leg) 1
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Remove”.
mandates. NOTICE
NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

component life.
g01077736
Illustration 38
Typical example
1. Remove the fasteners and remove tube assembly g01001918

Illustration 39
(6). Remove the O-ring seal from the tube
assembly.
KENR6232 25
1. Remove the bolt that holds drive gear (1) to the

shaft of engine oil pump (2). Use Tooling (A) to
remove the drive gear from the shaft. Remove the
key from the shaft.
g01103246
Illustration 41
1. Use a press and a suitable tool to install sleeve

bearings (4) in pump body (3). The bearing joint
Illustration 40
g01101672 should be 30 ± 15 degrees from the center line of
the two bearing bores. Install the sleeve bearings
so the sleeve bearings are even with the outside
of the pump body.
Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are re-

moved.
Be prepared to hold spring loaded covers as the

bolts are loosened.
2. Remove bolts (8). Remove retainer (5), spring (6),

and relief plunger (7) from pump body (3).
3. Remove bolts (9) and cover (10).

g01101732
4. Remove idler gear (12) and drive gear (13) from Illustration 42
the pump body.
2. Use a press and a suitable tool to install sleeve
5. Use a suitable tool to remove sleeve bearings (4) bearings (11) in cover (10). The bearing joint
from the pump body. should be 30 ± 15 degrees from the center line of
the two bearing bores. Install the sleeve bearings
6. Use a suitable tool to remove sleeve bearings (11) so the sleeve bearings are even with the outside
from the cover. of the cover.
i02554732
Engine Oil Pump - Assemble
Assembly Procedure
NOTICE

component life. Illustration 43
g01101672
26 KENR6232
i02554734
Engine Oil Pump - Install


assembly procedure and wear protective equip- Installation Procedure
ment.
NOTICE
3. Lubricate the idler gear and the drive gear with
clean engine oil. Lubricate sleeve bearings (4) Contaminants may cause rapid wear and shortened
with clean engine oil. Install idler gear (12) and component life.
drive gear (13) in pump body (3).
4. Lubricate sleeve bearings (11) with clean engine

oil. Install cover (10). Install bolts (9).
Note: The engine oil pump must turn freely after

assembly. Turn the engine oil pump by hand.
Reposition cover (10) if the engine oil pump does not
turn freely.
5. Install relief plunger (7), spring (6), retainer (5),

and bolts (8).
6. Install the key on the shaft.
g01077736
Illustration 45
Typical example
1. Position underframe assembly (3) on the cylinder

block. Install bolts (4). Tighten the bolts to a torque
of 47 N·m (35 lb ft).
2. Position engine oil pump (1) on the dowels in the

cylinder block. Install bolts (5). Tighten the bolts
Note: Ensure that the engine oil pump is seated on

the dowels before the bolts are tightened.
g01101743
Illustration 44
3. Install a new O-ring seal to tube assembly (6).
7. Install drive gear (1) on the shaft of engine oil Lubricate the bore in the engine oil pump with
pump (2). Install bolt (14). Tighten the bolt to a clean engine oil. Install tube assembly (6). Install
torque of 55 N·m (41 lb ft). the bolts that secure the tube assembly. Tighten
the bolts to a torque of 47 N·m (35 lb ft).
End By:
4. Install a new O-ring seal to the assembly of
a. Install the engine oil pump. Refer to Disassembly suction pipe (2). Lubricate the bore in the engine
and Assembly, “Engine Oil Pump - Install”. oil pump with clean engine oil. Install the assembly
of suction pipe (2). Install the bolts and washers
that secure the tube assembly. Tighten the bolts
End By:
a. Install the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and
Install”.
KENR6232 27
i02554791
Water Pump - Remove
Removal Procedure
NOTICE

mandates.
NOTICE

component life.
1. Drain the coolant from the cooling system into

a suitable container for storage or for disposal.
g01285782
Illustration 46
2. Remove bolts (2) from water temperature regulator

housing (1). Remove water temperature regulator
housing (1) and pipe (3) as a unit. Remove the
O-ring seals from the water temperature regulator
housing and the pipe.
3. Remove bolts (5). Remove water pump cover (4)

from water pump (8). Remove the O-ring seal from
the water pump cover.
4. Remove bolts (7). Remove oil cooler bonnet (6)

from the engine oil cooler. Remove the joint and
the O-ring seal from the oil cooler bonnet.
5. Remove the belt tightener. Refer to Disassembly

and Assembly, “Belt Tightener - Remove”.
6. Attach a suitable lifting device to water pump (8).

Support the weight of the water pump. The water
pump weighs approximately 18.3 kg (40 lb).
7. Remove bolts (9).
8. Use the lifting device in order to remove water

pump (8) from the front housing. Remove the
O-ring seal from the water pump.
28 KENR6232
i02554790 2. Use a suitable lifting device in order to position

water pump (8) on the front housing. The water
Water Pump - Install pump weighs approximately 18.3 kg (40 lb).
3. Install bolts (9). Tighten the bolts to a torque of

47 N·m (35 lb ft).
4. Install the belt tightener. Refer to Disassembly and
Table 15 Assembly, “Belt Tightener - Install”.
Required Tools
5. Install a new O-ring seal on oil cooler bonnet (6).
Tool Part Number Part Description Qty Apply Tooling (A) to the O-ring seal. Position the
POWERPART
joint and install oil cooler bonnet (6) to the engine
A 21820221 1 oil cooler. Install bolts (7). Tighten the bolts to a
Rubber Grease
NOTICE 6. Install a new O-ring seal to water pump cover (4).

Keep all parts clean from contaminants. Position water pump cover (4) on water pump (8)
and install bolts (5). Tighten the bolts to a torque
Contaminants may cause rapid wear and shortened of 47 N·m (35 lb ft).
component life.
7. Install new O-ring seals to pipe (3). Apply Tooling
(A) to the O-ring seals. Install the pipe in the
water temperature regulator housing (1). Install a
new O-ring seal to water temperature regulator
housing (1).
8. Insert pipe (3) into water pump cover (4). Install

the assembly of the water temperature regulator
housing and pipe as a unit. Install bolts (2).
Tighten the bolts to a torque of 47 N·m (35 lb ft).
9. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant
- Change”.
i02554792
Water Temperature Regulator

Housing - Remove and Install
Removal Procedure
NOTICE

g01285782 mandates.
Illustration 47
1. Install a new O-ring seal to water pump (8).
KENR6232 29
NOTICE

component life.
1. Drain the coolant from the cooling system into

a suitable container for storage or for disposal.
g01282552
Illustration 49
4. Remove water temperature regulator housing (1)

from housing manifold (2). Remove O-ring seal (7)
and O-ring seal (6) from the housing manifold.
5. Remove water temperature regulators (8).
6. Remove lip seal (10).
7. Remove pipe (4) from the water temperature

regulator housing. Remove O-ring seals (9) from
g01282550
Illustration 48 pipe (4).
Typical example
8. If necessary, remove coolant temperature sensor
2. Slide the locking tab into the unlocked position and (5). Refer to Disassembly and Assembly, “Coolant
disconnect the harness assembly from coolant Temperature Sensor - Remove and Install”.
temperature sensor (5).
3. Remove bolts (3). Remove pipe (4), water
temperature regulator housing (1), and housing Table 16
manifold (2).
Required Tools
A 27610309 Seal Installer 1
POWERPART
B 218200221 1
Rubber Grease
NOTICE

component life.
30 KENR6232
5. Loosely install bolts (3) to water temperature

regulator housing (1) and housing manifold (2).
Position water temperature regulator housing (1)
and housing manifold (2) onto pipe (4). Tighten
6. If necessary, install coolant temperature sensor

(5). Refer to Disassembly and Assembly, “Coolant
Temperature Sensor - Remove and Install”.
7. Connect the harness assembly to coolant

temperature sensor (5). Slide the locking tab into
the locked position.
8. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant
- Change”.
i02554737
g01282552
Engine Support (Front) -
Illustration 50
Remove and Install
1. Use Tooling (A) to install lip seals (10) into water
temperature regulator housing (1).
2. Install new O-ring seals (9) onto pipe (4). Apply Removal Procedure
Tooling (B) to the O-ring seals. Install pipe (4) to
the water pump. Table 17
Required Tools
3. Install O-ring seal (6) and O-ring seal (7) to
housing manifold (2). Tool Part Number Part Description Qty
- Guide Stud
4. Install water temperature regulators (8) into the A 2
(1/2 - 13 UNC by 6 inch)
water temperature regulator housing (1).
Start By:
a. Remove the assembly of the vibration damper

and the crankshaft pulley. Refer to Disassembly
and Assembly, “Vibration Damper and Pulley -
Remove and Install”.
1. Support the front of the engine.
g01282550
Illustration 51
Typical example
g01286145
Illustration 52
KENR6232 31
2. Remove bolts (1) and install Tooling (A). Remove End By:
the remaining bolts.
a. Install the assembly of the vibration damper
3. Remove engine support (2) from the cylinder and the crankshaft pulley. Refer to Disassembly
block. The weight of engine support (2) is and Assembly, “Vibration Damper and Pulley -
approximately 33.5 kg (74 lb). Remove and Install”.
Table 18 Flywheel - Remove

Required Tools
A - Guide Stud
2 Removal Procedure
(1/2 - 13 UNC by 6 inch)
Table 19
1. Support the front of the engine. Required Tools

Part
Tool Number Part Description Qty
- Guide Stud
A 2
5/8 - 18 by 8 inch
Start By:
a. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
NOTICE
g01286145
Illustration 53
2. Position engine support (2) on Tooling (A). The component life.
weight of engine support (2) is approximately
33.5 kg (74 lb).
3. Install bolts (1) finger tight. Remove Tooling (A)

and install the remaining bolts.
g01282130
Illustration 55
Typical example
1. Use a suitable tool to lock the flywheel. Loosen

bolts (1).
g01286401
Illustration 54
Tightening sequence 2. Attach a suitable lifting device to flywheel (1).
Support the weight of the flywheel. The weight of
4. Install bolts (1). Tighten the bolts to a torque of flywheel (2) is approximately 130 kg (286 lb).
105 N·m (77 lb ft) in the order that is shown in
Illustration 54. 3. Remove two bolts (1). Install Tooling (A).
32 KENR6232
4. Remove the remaining bolts (1). Use the lifting

device in order to remove flywheel (2).
g01091705
Illustration 57
g01091705
Illustration 56
Typical example
Always wear protective gloves when handling
5. Inspect flywheel (2) and ring gear (3) for wear or parts that have been heated.
damage. Replace any components that are worn
or damaged.
1. If the flywheel ring gear was removed, follow
6. To remove the flywheel ring gear, follow Steps 6.a Steps 1.a through 1.c in order to install a new ring
gear to the flywheel.
and 6.b.
a. Place the flywheel assembly on a suitable a. Identify the orientation of the teeth on the new
ring gear (3).
support.
Note: Identify the orientation of the teeth on the Note: The chamfered side of the ring gear teeth must
face toward the starting motor when the flywheel is
flywheel ring gear.
installed. This will ensure the correct engagement of
b. Use a hammer and a punch in order to remove the starting motor.
ring gear (3) from flywheel (2).
b. Heat flywheel ring gear (3) in an oven to a
maximum temperature of 316 °C (600 °F) prior
i02554744 to installation.
Flywheel - Install Note: Do not use a torch to heat the ring gear.
c. Ensure that the orientation of ring gear (3) is

correct and quickly install the ring gear onto
Installation Procedure flywheel (2).
Table 20 2. Inspect the crankshaft rear seal for leaks. If there

are any oil leaks, replace the crankshaft rear seal.
Required Tools
Refer to Disassembly and Assembly, “Crankshaft
Tool Part Number Part Description Qty Rear Seal - Remove”.
- Guide Stud
A 2
5/8 - 18 by 8 inch
NOTICE

component life.
KENR6232 33
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
NOTICE

component life.
Note: The crankshaft rear seal and the wear sleeve

must be replaced as a unit. Once the crankshaft
g01282130
rear seal and the wear sleeve are separated, these
Illustration 58 components can not be used again.
Typical example
3. Install a suitable lifting device to flywheel (1). The

weight of flywheel (2) is approximately 130 kg
(287 lb).
4. Install Tooling (A) on the crankshaft.
5. Use the lifting device in order to position flywheel

(1) onto Tooling (A).
6. Apply clean engine oil to the threads of bolts (1).
7. Install bolts (1). Remove Tooling (A). Install

remaining bolts (1).
8. Use a suitable tool to prevent the flywheel from

rotating. Tighten bolts (1) to a torque of 270 N·m
(200 lb ft).
9. Remove the lifting device from flywheel (1).

g01007851
Illustration 59
10. Check the runout of the flywheel. Refer to
Systems Operations, Testing and Adjusting, Typical example
“Flywheel - Inspect”.
1. Use a 4 mm (0.158 inch) drill in order to make
End By: three or more holes in wear sleeve (2).
a. Install the electric starting motor. Refer to 2. Use Tooling (A) to remove the wear sleeve.
Motor - Remove and Install”. 3. Use a 4 mm (0.158 inch) drill in order to make
three or more holes in crankshaft rear seal (1).
i02554710 4. Use Tooling (A) to remove crankshaft rear seal (1).

Crankshaft Rear Seal - Remove
Removal Procedure
Table 21
Required Tools
Part
A 27610311 Slide Hammer Puller 1
34 KENR6232
i02554709 1. Before installation of the crankshaft seal and the

wear sleeve, inspect the crankshaft for scratches.
Crankshaft Rear Seal - Install Also, inspect the crankshaft for any distortion
on the surface that may lead to an out of round
condition. Use a polishing cloth in order to remove
any imperfections on the crankshaft.
2. Clean the outside diameter of the crankshaft and
Table 22 the inside diameter of the wear sleeve.
Required Tools
3. Fasten Tooling (B) to the crankshaft with Tooling
Part (C).
B GE50008 Seal Locator 1 Note: Install the crankshaft rear seal with the arrow
that shows the direction of crankshaft rotation toward
C GE50009 Bolt 3 the rear of the engine.
D GE50014 Nut (Seal Installer) 1
4. Position wear sleeve (2) and crankshaft rear seal
E GE50013 Seal Installer 1 (1) on Tooling (B). Install Tooling (E) on Tooling
(B). Lubricate the face of the washer on Tooling
(D). Install Tooling (D) on Tooling (B).
NOTICE
Keep all parts clean from contaminants. 5. Tighten Tooling (D) until Tooling (E) contacts
Tooling (B).
component life. 6. Remove Tooling (D) and Tooling (E) from Tooling
(B).
Note: Do not lubricate the crankshaft seal or the wear
sleeve. The crankshaft seal must be installed dry. 7. Remove Tooling (C) and Tooling (B) from the
crankshaft.
8. Check the crankshaft rear seal and the wear

sleeve for the correct installation.
End By:
a. Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.
i02554749
Flywheel Housing - Remove

and Install
Removal Procedure
Table 23
g01007913 Required Tools
Illustration 60
Typical example Tool Part Number Part Description Qty
Note: Do not use any type of lubricant during the - Guide Stud
A 2
installation of the crankshaft seal and wear sleeve. (3/8 - 16 x 4inch)
KENR6232 35
Start By: 3. Remove remaining bolts (2). Use the suitable

lifting device to remove the flywheel housing from
a. Remove the electric starting motor. Refer to the cylinder block.
Motor - Remove”. Note: It is not necessary to remove the dowels in the
cylinder block that locate the flywheel housing.
b. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear Installation Procedure
Seal - Remove”.
Table 24
c. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and Required Tools
Install”. Tool Part Number Part Description Qty
- Guide Stud
NOTICE A
(3/8 - 16 x 4inch)
2
during performance of inspection, maintenance, test- B CH10879 Sealant 1
ing any compartment or disassembling any compo- NOTICE
nent containing fluids. Keep all parts clean from contaminants.
Dispose of all fluids according to local regulations and Contaminants may cause rapid wear and shortened
mandates. component life.
1. Thoroughly clean the flywheel housing and the

NOTICE
rear surface of the cylinder block. Ensure that the
dowels in the cylinder block protrude 1.91 cm
(0.75 inch) from the mating surface.
component life.
g01287855
Illustration 62
g01287855
Typical example
Illustration 61
Typical example 2. Install Tooling (A) in the cylinder block.
1. Install a suitable lifting device to flywheel housing 3. Install a suitable lifting device to flywheel housing
(1). The weight of the flywheel housing is (1). The weight of the flywheel housing is
approximately 86 kg (190 lb). approximately 86 kg (190 lb).
2. Remove two bolts (2). Install Tooling (A). 4. Apply Tooling (B) to the rear face of the cylinder
block.
36 KENR6232
Note: The flywheel housing must be installed within i02554787

ten minutes of applying Tooling (B).
Vibration Damper and Pulley -
5. Use the suitable lifting device to align flywheel Remove and Install
housing (1) with Tooling (A). Install the flywheel
housing to the cylinder block. Install bolts (2)
finger tight. Remove Tooling (A) and install the
remaining bolts.
Removal Procedure
Table 25
Required Tools
- Guide Stud
A 2
(5/8 - 18 x 9 inch)
Start By:
a. Remove the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.
NOTICE

component life.
g00551652
Illustration 63
Tightening sequence
Typical example
6. Tighten the bolts, as follows:
a. In the numerical sequence, tighten bolt 1

through bolt 9 to a torque of 100 N·m (74 lb ft).
b. In the numerical sequence, tighten bolt 10

c. In the numerical sequence, tighten bolt 1

d. In the numerical sequence, tighten bolt 10

End By:
g01285717
a. Install the crankshaft rear seal. Refer to Illustration 64
Disassembly and Assembly, “Crankshaft Rear
Seal - Install”. 1. Loosen nut (1). Rotate bolt (2) in order to release
the tension on the V-belts.
b. Install the engine oil pan. Refer to Disassembly
Install”.
c. Install the electric starting motor. Refer to

Motor - Remove and Install”.
KENR6232 37
Table 26
Required Tools
- Guide Stud
A 2
(5/8 - 18 x 9 inch)
B CV60890 Anti-Seize Compound -
NOTICE
Illustration 65
g01286051 Contaminants may cause rapid wear and shortened
component life.
Typical example
2. Remove the V-belts from crankshaft pulley (6). NOTICE

Temporarily secure the V-belts in a position that Thoroughly inspect the viscous damper for signs of
is clear of vibration damper (4). leakage or for signs of a dented (damaged) case.
Either of these conditions can cause the weight to
3. Remove two bolts (5). Install Tooling (A). make contact with the case. This can affect the vis-
cous damper’s operation.
4. Remove remaining bolts (5). Remove crankshaft
pulley (6).
Note: Ensure that the weight of the assembly of

vibration damper (4) and adapter (3) is adequately
supported.
5. Install a suitable lifting device to the assembly of

vibration damper (4) and adapter (3). The weight
of the assembly of the vibration damper and the
adapter is approximately 50 kg (110 lb).
6. Use the lifting device to remove the assembly of

vibration damper (4) and adapter (3) from the
crankshaft.
g01286057
7. Remove Tooling (A) from the crankshaft. Illustration 67
1. Inspect the components for damage. Replace any

components that are damaged.
2. 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”.
3. Position vibration damper (4) on adapter (3). The

weight of vibration damper (4) is approximately
34 kg (75 lb).
4. Use Tooling (B) to lubricate threads of bolts (7).

Install bolts (7) and tighten the bolts to a torque of
Illustration 66
g01286057 105 N·m (77 lb ft).
8. Remove bolts (7). Remove vibration damper (4)

from adapter (3). The weight of vibration damper
(4) is approximately 34 kg (75 lb).
38 KENR6232
g01286051
Illustration 68
Typical example
5. Install Tooling (A) in the crankshaft.
6. Install a suitable lifting device to the assembly of

vibration damper (4) and adapter (3). The weight Illustration 69
g01285717
of the assembly of the vibration damper and the
adapter is approximately 50 kg (110 lb). Use the 11. Position the V-belts on crankshaft pulley (6) and
lifting device to align the assembly of the vibration the pulley of the belt tightener.
damper and the adapter with Tooling (A).
12. Rotate bolt (2) in order to adjust the tension of
7. Install the assembly of adapter (3) and vibration the V-belts. Refer to Operation and Maintenance
damper (4) to the crankshaft. Manual, “Belt Tension Chart”.
8. Remove the lifting device. 13. Tighten nut (1).
Note: Ensure that the weight of the assembly of End By:
vibration damper (4) and adapter (3) is adequately
supported. a. Install the fan. Refer to Disassembly and
9. Install crankshaft pulley (6) on Tooling (A).
10. Apply Tooling (B) to bolts (5). Install the bolts. i02554705
Remove Tooling (A) and install the remaining
bolts. Tighten the bolts to a torque of 270 N·m Crankshaft Front Seal -
(200 lb ft). Remove
Removal Procedure
Table 27
Required Tools
Part
A 27610311 Slide Hammer Puller 1
Start By:
a. Remove the assembly of the vibration damper

KENR6232 39
i02554704
NOTICE
Crankshaft Front Seal - Install
component life.
Note: The crankshaft front seal and the wear sleeve Table 28
must be replaced as a unit. Once the crankshaft
front seal and the wear sleeve are separated, these Required Tools
components can not be used again. Part
B GE50008 Seal Locator 1
C GE50009 Bolt 3
D GE50014 Nut (Seal Installer) 1
E GE50013 Seal Installer 1
NOTICE

component life.
Note: The crankshaft front seal and the wear

sleeve must be replaced at the same time. Once
the crankshaft front seal and the wear sleeve are
separated, these components cannot be used again.
Note: Do not lubricate the crankshaft seal or the wear

g01044861 sleeve. The crankshaft seal must be installed dry.
Illustration 70
Typical example
1. Before installation of the crankshaft front seal
1. Use a 4 mm (0.158 inch) drill in order to make and the wear sleeve, inspect the crankshaft for
three or more holes in wear sleeve (2). scratches. Also, inspect the crankshaft for any
distortion on the surface that may lead to an out of
2. Use Tooling (A) to remove the wear sleeve. round condition. Use a polishing cloth in order to
remove any imperfections on the crankshaft.
3. Use a 4 mm (0.158 inch) drill in order to make
three or more holes in crankshaft front seal (1). 2. Clean the outside diameter of the crankshaft.
4. Use Tooling (A) to remove crankshaft front seal

(1).
40 KENR6232
i02554751
Front Cover - Remove
Removal Procedure
Start By:
a. Remove the fan drive. Refer to Disassembly and

Assembly, “Fan drive - Remove”.
b. Remove the assembly of the vibration damper

NOTICE
g01056093
Illustration 71 ing, adjusting and repair of the product. Be prepared to
Typical example collect the fluid with suitable containers before open-
3. Fasten Tooling (B) to the crankshaft with Tooling nent containing fluids.
(C).
Note: Install the crankshaft front seal with the arrow mandates.
that shows the direction of crankshaft rotation toward
the front of the engine.
NOTICE
4. Position wear sleeve (2) and crankshaft front seal Keep all parts clean from contaminants.
(1) on Tooling (B). Install Tooling (E) on Tooling
(B). Lubricate the face of the washer on Tooling Contaminants may cause rapid wear and shortened
(D). Install Tooling (D) on Tooling (B). component life.
5. Tighten Tooling (D) until Tooling (E) contacts

Tooling (B).
6. Remove Tooling (D) and Tooling (E) from Tooling

(B).
7. Remove Tooling (C) and Tooling (B) from the

crankshaft.
End By:
a. Install the vibration damper and the pulley. Refer

to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
g01286405
Illustration 72
1. Loosen bolts (2). Remove front cover (3) from

front housing (1).
KENR6232 41
2. Remove bolts (2) and seal (4) from front cover (3).
i02554750
Front Cover - Install
NOTICE

component life.
g01286471
Illustration 74
Tightening sequence
2. Position front cover (3) on front housing (1).

Tighten the bolts to a torque of 20 N·m (15 lb ft)
in the numerical sequence that is shown in
Illustration 74.
End By:
a. Install the assembly of the vibration damper

b. Install the fan drive. Refer to Disassembly and

g01286405 Assembly, “Fan drive - Install”.
Illustration 73
1. Install seal (4) and bolts (2) to front cover (3). i02554763
Gear Group (Front) - Remove
Removal Procedure
Start By:
a. Remove the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove and
Install”.
NOTICE

component life.
42 KENR6232
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
Note: Be sure to mark the orientation of each of the

gears for installation purposes.
g01287363
Illustration 77
Typical example
5. Remove bolts (11), plate (12), and idler gear

assembly (10).
g01287358
Illustration 75
1. Remove bolts (2) and thrust plate (1). g01287364

Illustration 78
2. Remove sealing plate (3) and adapter (4). Typical example
3. Remove O-ring seal (5) and O-ring seal (6) from 6. Remove bolts (14), plate (15), and cluster gear
sealing plate (3). assembly (13).
g01287359
Illustration 76
Typical example
4. Remove bolts (8), plate (9), and adjustable idler

gear assembly (7).
KENR6232 43
NOTICE
g01287365
Illustration 79
Typical example
Note: The backlash for the camshaft gear and

the adjustable idler gear assembly will need to be
readjusted at assembly.
7. Remove fasteners (17) and remove stub shaft g01287373

assembly (16). Illustration 80
Typical example
8. Remove fasteners (19) and remove stub shaft
(18). 1. Install stub shaft (20). Apply Tooling (B) to bolts
(21). Install bolts (21) and tighten to a torque of
9. Remove bolts (21) and remove stub shaft (20). 55 N·m (40 lb ft) in sequence. (1, 3, 4, 5, 2, 1, 2,
3, 4, 5, 1)
i02554762 Note: If any studs are loose or the threads are

damaged, install new studs to the front housing.
Gear Group (Front) - Install
2. Install stub shaft (18). Apply Tooling (A) to the
studs and the bolt for stub shaft (18). Tighten nuts
(19) and the bolt to a torque of 55 N·m (40 lb ft).
3. Install stub shaft assembly (16). Do not tighten
Table 29 nuts (17) and the bolt for the shaft assembly at
Required Tools this time. The nuts and the bolt for stub shaft
assembly (16) will need to be tightened when the
Tool Part Number Part Description Qty backlash is adjusted.
POWERPART
A 21820117 1 Note: If shaft assembly (16) is removed, the backlash
Threadlock and Nutlock
for the camshaft gear and the adjustable idler
POWERPART gear will need to be readjusted. Refer to Systems
B 21820221 1
Rubber Grease Operation, Testing and Adjusting, “Gear Group
(Front) - Time”.
NOTICE

component life.
44 KENR6232
8. Apply Tooling (A) to bolts (14). Position plate

(15) with the oil groove toward the gear face.
Install bolts (14) and tighten to a torque of 28 N·m
(21 lb ft).
g01287363
Illustration 83
Typical example
g01287358
Illustration 81
9. Position idler gear (10) on the shaft assembly.
4. Install new O-ring seals (5) and (6) to sealing plate
(3). Lubricate O-ring seal (5) with Tooling (B). 10. Apply Tooling (A) to bolts (11). Position plate
(12) with the oil groove toward the gear face.
5. Install adapter (4). Ensure that the dowel in the Install bolts (11) and tighten to a torque of 28 N·m
adapter engages the hole in the camshaft. (21 lb ft).
6. Install sealing plate (3) and thrust plate (1) in the 11. Install the camshaft gear. Refer to Disassembly
front housing. Apply Tooling (A) to bolts (2). Install and Assembly, “Camshaft Gear - Remove and
bolts (2) and tighten the bolts to a torque of 12 N·m Install.” for the correct procedure.
(106 lb in). Ensure that sealing plate (3) and O-ring
seal (6) are seated against the cylinder head. 12. Check the backlash for the camshaft gear and
the adjustable idler gear. If necessary, adjust the
Note: Ensure that No. 1 piston at the top center backlash. Refer to Systems Operation, Testing
position on the compression stroke. Refer to Systems and Adjusting, “Gear Group (Front) - Time”.
Operation, Testing and Adjusting, “Finding Top
Center Position for No. 1 Piston”. Note: The camshaft gear must be installed and the
adjustable idler gear must be removed in order to
perform the backlash adjustment procedure.
g01287378
Illustration 82
Typical example
g01288571
Illustration 84
7. Put cluster gear assembly (13) on the stub shaft.
Ensure that Timing Marks (V) are aligned on the 13. Once the correct backlash has been obtained,
cluster gear assembly and the crankshaft gear. follow Steps 13.a through 13.d in order to secure
stub shaft assembly (16).
KENR6232 45
a. Remove one nut (17). b. Remove the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
b. Apply Tooling (A) to the nut. Sensor - Remove and Install”.
c. Install nut (17) and tighten to a torque of c. Remove the belt tightener. Refer to Disassembly
55 N·m (40 lb ft). and Assembly, “Belt Tightener - Remove”.
d. Repeat the procedure for the remaining nuts d. Remove the fuel transfer pump. Refer to
and the bolt. Disassembly and Assembly, “Fuel Transfer Pump
- Remove”.
Note: Removing and installing one nut at time will
ensure that the position of the stub shaft assembly e. Remove the water pump. Refer to Disassembly
is not affected. and Assembly, “Water Pump - Remove”.
Note: Ensure that the timing mark on the camshaft f. Remove the gear group (front). Refer to
gear is aligned with the timing mark on the front Disassembly and Assembly, “Gear Group (Front)
housing before the adjustable idler gear assembly - Remove ”.
is installed.
g. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
h. Remove the engine oil pan. Refer to Disassembly

Install”.
i. Remove the engine support. Refer to Disassembly

and Assembly, “Engine Support (Front) - Remove
and Install”.
NOTICE
g01287359 during performance of inspection, maintenance, test-
Illustration 85
Typical example collect the fluid with suitable containers before open-
14. Put adjustable idler gear assembly (7) on the nent containing fluids.
stub shaft assembly. Position plate (9) with the oil
groove toward the face of the gear. Apply Tooling Dispose of all fluids according to local regulations and
(A) to bolts (8). Install bolts (8). Tighten bolts (8) mandates.
End By: NOTICE

a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Install”. Contaminants may cause rapid wear and shortened
component life.
i02554765
NOTICE
Housing (Front) - Remove Do not turn the crankshaft or the camshaft while the
Removal Procedure damage to the engine.
Start By:
a. Remove the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
46 KENR6232
NOTICE
g01286831
Illustration 86
1. Remove bolts (3) and bracket (2).
2. Remove the brackets that support the harness

assembly.
3. Use a suitable lifting device to support the weight

g01286831
of front housing (1). The front housing weighs Illustration 87
approximately 62 kg (137 lb).
1. Thoroughly clean the mating surfaces of the
4. Remove bolts (4). cylinder block and front housing (1). Ensure that
the dowels in the cylinder block protrude 1.91 cm
5. Use the lifting device to remove front housing (1). (0.75 inch) from the mating surface.
6. Remove joint (5). 2. Install a new joint (5) on the dowels in the cylinder
block.
Note: It is not necessary to remove the dowels in the
cylinder block that locate the front housing. Note: Trim the joint even with the bottom of the front
housing after assembly.
i02554764 3. Use a suitable lifting device to align front housing

(1) with the dowels in the cylinder block. The front
Housing (Front) - Install housing weighs approximately 62 kg (137 lb).
4. Install front housing (1) to the cylinder block.

Install bolts (4). Tighten the bolts to a torque of
Installation Procedure 50 N·m (37 lb ft).
NOTICE 5. Position bracket (2) and install bolts (3). Ensure

Keep all parts clean from contaminants. that the bracket that supports the harness
assembly is secured by the appropriate bolt.
Contaminants may cause rapid wear and shortened Tighten the bolts to a torque of 47 N·m (35 lb ft).
component life.
6. Install the remaining bracket that supports the
harness assembly.
KENR6232 47
End By:
a. Install the engine support. Refer to Disassembly

and Assembly, “Engine Support (Front) - Remove
and Install”.
b. Install the engine oil pan. Refer to Disassembly

Install”.
c. Install the crankshaft front seal. Refer to

Disassembly and Assembly, “Crankshaft Front
Seal - Install”.
d. Install the gear group (front). Refer to Disassembly g01286833

and Assembly, “Gear Group (Front) - Install ”. Illustration 88
e. Install the water pump. Refer to Disassembly and 1. Loosen clamp (2) and remove hose (3) from
Assembly, “Water Pump - Install”. connection (1) on the valve mechanism cover.
Remove the hose.
f. Install the fuel transfer pump. Refer to Disassembly
and Assembly, “Fuel Transfer Pump - Install”. Installation Procedure
g. Install the belt tightener. Refer to Disassembly and NOTICE
Assembly, “Belt Tightener - Install”. Keep all parts clean from contaminants.
h. Install the crankshaft position sensor. Refer to Contaminants may cause rapid wear and shortened
Disassembly and Assembly, “Crankshaft Position component life.
i. Install the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position
i02554701
Crankcase Breather - Remove

and Install
(Open Breather)
Removal Procedure Illustration 89

g01286833
NOTICE 1. Ensure that hose (3) is clean and free from

Keep all parts clean from contaminants. damage.
Contaminants may cause rapid wear and shortened 2. Install hose (3) to connection (1) on the valve
component life. mechanism cover. Tighten clamp (2).
48 KENR6232
i02554786
Valve Mechanism Cover -

Remove and Install
Removal Procedure
NOTICE

component life. g01283967
Illustration 91
Tightening sequence for the valve mechanism cover
3. Gradually loosen isolated bolts (1) in reverse

numerical order. Refer to Illustration 91. This will
help prevent distortion of the valve mechanism
cover.
4. Remove the valve mechanism cover (2). Remove

isolated bolts (1) and joint (4) from the valve
mechanism cover.
NOTICE

component life.
g01283965
Illustration 90
1. Loosen clip (5) and remove breather hose (6) from

valve mechanism cover (2).
2. Disconnect the harness assembly from connector

(3). Remove the bolts and the washers that secure
the connector to valve mechanism cover (2).
g01283965
Illustration 92
1. Install isolated bolts (1) and a new joint (4) to valve

mechanism cover (2).
KENR6232 49
g01283967
Illustration 93
Tightening sequence for the valve mechanism cover
2. Install valve mechanism cover (2). Gradually

tighten the isolated bolts (1) to a torque of 20 N·m
(15 lb ft) in the numerical sequence that is shown
in Illustration 93. Illustration 94
g01047470
3. Position connector (3) into valve mechanism cover

(2). Install the bolts and the washers that secure
the connector to the valve mechanism cover.
Torque the bolts to a torque of 1.5 N·m (13 lb in). Valve rocker arms and unit injector rocker arms
Connect the harness assembly to the connector. can move on the shaft after the bolts have been
removed. The shaft should be kept level when re-
4. Install clip (5) and breather hose (6) to valve moved from the cylinder head. To avoid possible
mechanism cover (2). personal injury, keep fingers clear of the valve
rocker arms and the unit injector rocker arms
when lifting the assembly from the cylinder head.
i02554783
Rocker Arm and Shaft - 1. Remove bolts (2).

Remove 2. Use Tooling (A) to remove rocker arm shaft
assembly (4), valve rocker arms (3), and electronic
unit injector rocker arms (1) as a unit.
Removal Procedure 3. Make a temporary mark on the valve bridges in

order to show the location and the orientation.
Table 30 Remove the valve bridges from the cylinder head.
Required Tools
Note: Identification will ensure that the valve bridges
Part can be reinstalled in the original location and the
Tool Number Part Description Qty original orientation. Do not interchange the location
A 27610322 Lifting Bracket 1 or the orientation of used valve bridges.
Start By: i02554781
a. Remove the valve mechanism cover. Refer to Rocker Arm - Disassemble

Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
NOTICE Disassembly Procedure

Start By:
component life. a. Remove the rocker arms and the rocker shaft.
50 KENR6232
i02554780
NOTICE
Rocker Arm - Assemble
component life.
Assembly Procedure
NOTICE

component life.
g01047557
Illustration 95
1. Remove valve rocker arms (11) and electronic unit

injector rocker arm (3) from rocker shaft assembly
(4).
2. Remove nut (7) from adjustment screw (8).

g01047557
Illustration 96
3. Remove adjustment screw (8) from valve rocker
arms (11).
Note: Do not reuse the O-ring seal on the adjustment
screw if the button is removed from the adjustment
4. Remove button (10) from adjustment screw (8).
screw.
Remove O-ring seal (9) from the adjustment
screw.
1. Install a new O-ring seal (9) in button (10).
5. Remove nut (2) from unit injector adjustment
2. Use a soft hammer to seat button (10) on
screw (1).
adjustment screw (8).
6. Remove unit injector adjustment screw (1) from
3. Install adjustment screw (8) in valve rocker arms
electronic unit injector rocker arm (3).
(11). Install nut (7) on the adjustment screw.
7. Remove button (6) from unit injector adjustment
4. Install a new O-ring seal (5) in button (6).
screw (1). Remove O-ring seal (5) from the unit
injector adjustment screw.
5. Use a soft hammer to seat button (6) on unit
injector adjustment screw (1).
6. Install unit injector adjustment screw (1) in

electronic unit injector rocker arm (3). Install nut
(2) on the unit injector adjustment screw.
7. Lubricate rocker shaft assembly (4) with clean

engine oil.
8. Install valve rocker arms (11) and electronic unit

injector rocker arm (3) on rocker shaft assembly
(4).
KENR6232 51
End By: 3. Install bolts (2) and tighten to a torque of 109 N·m
(80 lb ft).
a. Install the rocker arms and the rocker shaft. Refer
to Disassembly and Assembly, “Rocker Arm and 4. Adjust the valve lash for the inlet valves and the
Shaft - Install”. exhaust valves. Refer to Systems Operation,
Testing and Adjusting, “Engine Valve Lash
- Inspect/Adjust”. Adjust the electronic unit
i02554782
injectors. Refer to Systems Operation, Testing and
Rocker Arm and Shaft - Install Adjusting, “Electronic Unit Injector - Adjust”.
End By:
a. Install the valve mechanism cover. Refer to

Installation Procedure Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
Table 31
Required Tools
i02554713
A 27610322 Lifting Bracket 1
Cylinder Head - Remove
NOTICE
Keep all parts clean from contaminants. Removal Procedure
Contaminants may cause rapid wear and shortened Table 32
component life. Required Tools
1. Install the valve bridges.
A GE50020 Socket 1
Note: Install used valve bridges in the original B VP12712 Lifting Bracket 1
location and in the original orientation. Ensure that the
valve bridges are correctly seated on the valves. New
valve bridges may be installed in either orientation. Start By:
a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.
b. Remove the electronic unit injectors. Refer to

c. Remove the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove”.
d. Remove the water temperature regulator housing.

Install ”.
NOTICE
g01117306 ing any compartment or disassembling any compo-
Illustration 97
2. Use Tooling (A) in order to position rocker arm Dispose of all fluids according to local regulations and
shaft assembly (4), valve rocker arms (3), and mandates.
electronic unit injector rocker arms (1) as a unit,
on the cylinder head.
52 KENR6232
NOTICE

component life.
NOTICE
g01067185
Illustration 99
Typical example
4. Disconnect hose assembly (8) from the front of the

cylinder head. Remove the bolt and the clip that
secures the hose assembly to the cylinder head.
5. Disconnect hose assembly (9) from the rear of the

cylinder head. Remove the bolt and the clip that
secures the hose assembly to the cylinder head.
6. Remove bolt (14), the clip and the spacer. Remove

the crankcase breather from the cylinder head.
7. Remove bolts (7) and remove the bracket from

the cylinder head.
8. Slide the locking tab into the unlocked position

and disconnect the harness assembly from inlet
manifold pressure sensor (10).
g01287358
Illustration 98 9. Slide the locking tab into the unlocked position
and disconnect the harness assembly from inlet
1. Remove bolts (2) and thrust plate (1). manifold temperature sensor (13).
2. Remove sealing plate (3) and adapter assembly 10. Remove the bolts and the clips that secure the
(4). harness assembly to the cylinder head.
3. Remove O-ring seal (5) and O-ring seal (6) from 11. Remove bolts (12), the bracket and air inlet elbow
sealing plate (3). (11) from the cylinder head. Remove the O-ring
seal from the air inlet elbow.
Note: Be sure to mark the orientation of the air inlet

elbow for installation purposes.
KENR6232 53
g01288987
Illustration 100
Typical example
12. Remove bolts (15) from the front lifting bracket.
g01288989
Illustration 102
Typical example
16. Remove cylinder head gasket (18) and O-ring

seal (19).
17. Remove seal (22) and seals (24).
18. Remove spacer plate (21).
19. Remove O-ring seal (20) from the dowel in the

cylinder block. Remove spacer plate gasket (24).
g01288988
Illustration 101
Typical example i02554711
13. Use Tooling (A) in order to remove cylinder head Cylinder Head - Install
bolts (16).
14. Attach Tooling (B) and a suitable lifting device

to cylinder head (17). The weight of the cylinder Installation Procedure
head assembly is approximately 235 kg (518 lb).
Ensure that all of the following items are clear Table 33
from the cylinder head: harness assemblies, tube
Required Tools
assemblies, and hose assemblies.
Part
15. Use the lifting device to carefully remove cylinder Tool Number Part Description Qty
head (17). A GE50020 1
Socket
B VP12712 Lifting Bracket 1
C - Guide Stud 2
POWERPART
D CV60895 1
Special Lubricant
POWERPART
E 21820221 1
Rubber Grease
POWERPART
F 2182638 1
Retaining Compound
54 KENR6232
NOTICE

component life.
g01288718
Illustration 104
Typical example
6. Install Tooling (C) to the cylinder block in the

positions that are shown in Illustration 104.
g01288989
Illustration 103
Typical example
Note: Thoroughly clean the spacer plate and the

bottom surface of the cylinder head and the top of
the cylinder block. A new spacer plate gasket and
a cylinder head gasket must be installed when the g01288988
Illustration 105
cylinder head is removed.
Typical example
1. Install O-ring seal (20) on the dowel in the cylinder
block. 7. Attach Tooling (A) and a suitable lifting device to
cylinder head (17). The weight of cylinder head
Note: Ensure that the dowel protrudes from assembly (17) is approximately 235 kg (518 lb).
the face of the cylinder block by 20 ± 0.5 mm
(0.79 ± 0.02 inch). 8. Use the lifting device to align cylinder head (17)
with Tooling (C). Carefully install the cylinder head
2. Install spacer plate gasket (23) on the cylinder onto the dowel pins in the cylinder block.
block.
9. Remove Tooling (A).
3. Install spacer plate (21).
10. Apply Tooling (D) to the threads of cylinder head
4. Install seals (24) and seal (22). bolts (16) and both sides of the washers. Install
cylinder head bolts (16).
5. Install cylinder head gasket (18) on the spacer
plate. Install O-ring seal (19) on the dowel in the
cylinder block.
g01072801
Illustration 106
KENR6232 55
Note: The bolts that are Marked “X” are 216 mm 15. Connect hose assembly (8) to the cylinder head.
(8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24, and Install the bolt and the clip that secures the hose
26. The rest of the bolts are 194 mm (7.6 inch) long. assembly to the cylinder head.
11. Tighten the cylinder head bolts according to the 16. Install bolt (14), the clip and the spacer that
following procedure. secures the breather tube to the cylinder head.
Tighten bolt (14) to a torque of 10 N·m (89 lb in).
a. In the numerical sequence, tighten Bolts 1
through 26 to a torque of 270 N·m (200 lb ft). 17. Position the bracket on the cylinder head and
install bolts (7). Tighten the bolts to a torque of
b. In the numerical sequence, tighten Bolts 1 47 N·m (35 lb ft).
through 26 to a torque of 450 N·m (330 lb ft).
18. Connect the harness assembly to inlet manifold
c. In the numerical sequence, again tighten Bolts pressure sensor (10). Slide the locking tab into
1 through 26 to a torque of 450 N·m (330 lb ft). the locked position.

20. Install the bolts and the clips that secure the
harness assembly to the cylinder head.
g01288987
Illustration 107
12. Install bolts (15) to the front lifting bracket. Tighten

g01287358
Illustration 109
21. Install O-ring seal (5) and O-ring seal (6) on

sealing plate (3). Lubricate O-ring seal (5) with
Tooling (E).
g01067185
Illustration 108
22. Install adapter assembly (4) and sealing plate (3).
Typical example
Ensure that the dowel in adapter assembly (4)
engages the hole in the camshaft.
13. Install a new O-ring seal to air inlet elbow (11).
Position the bracket and air inlet elbow (11) on the
Note: Ensure that the O-ring seal stays in the groove
cylinder head. Install bolts (12) and tighten to a
in sealing plate (3).
23. Install thrust plate (1). Apply Tooling (F) to bolts
Note: Ensure that the air inlet elbow is installed in the
(2). Hold the thrust plate in position and install
correct orientation.
bolts (2). Evenly tighten bolts (2) to a torque of
12 N·m (106 lb in).
14. Connect hose assembly (9) to the cylinder head.
Install the bolt and the clip that secures the hose
assembly to the cylinder head.
56 KENR6232
Note: Ensure that the O-ring seal stays in the groove

in sealing plate (3). NOTICE
End By: camshaft gear is removed. If the front gear group is
a. Install the camshaft gear. Refer to Disassembly occur between the pistons and the valves, resulting in
and Assembly, “Camshaft Gear - Install”. damage to the engine.
b. Install the electronic unit injectors. Refer to

Injector - Install”.
c. Install the water temperature regulator housing.

Install”.
d. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.
i02554691
Camshaft - Remove
Removal Procedure
Table 34 g01287358
Illustration 110
Required Tools
1. Remove bolts (2) and thrust plate (1).
A GE50018 Cradle 1 2. Remove sealing plate (3) from the front housing.
Remove adapter assembly (4) from the camshaft.
B GE50017 Guide 1
C GE50015 Camshaft Pilot 2 3. Remove O-ring seal (5) and O-ring seal (6) from
sealing plate (3).
D GE50025 Camshaft Hook 2
NOTICE
Start By: Care must be used when removing or installing the
camshaft. Do not damage the finshed surfaces of the
a. Remove the camshaft gear. Refer to Disassembly camshaft or the camshaft bearings.
Install”.
b. Remove the rocker arms and the rocker shafts.

NOTICE

component life.
g01286820
Illustration 111
Typical example
KENR6232 57
4. Use the bolts for the rocker arm shaft assembly to

install Tooling (A) at Location (Y).
g01047996
Illustration 115
Typical example
g01047945
Illustration 112
Typical example 7. Move camshaft (8) forward and install one Tooling
(C) to the end of the camshaft. Again, move the
5. Install Tooling (B) on front housing (7). Tooling (B) camshaft forward and install remaining Tooling (C)
is used to support camshaft (8). Do not tighten the to the back of first Tooling (C). Align camshaft (8)
bolts for Tooling (B) at this time. with the bore of Tooling (B). Tighten the bolts that
hold Tooling (B) to front housing (7).
Note: Tooling (C) will support the rear of the camshaft

as the camshaft is moved out of the cylinder head
and into Tooling (B).
8. Use Tooling (D) to move camshaft (8) toward the

front of the engine. Reposition Tooling (D), as
required.
Note: Avoid lifting the camshaft with Tooling (D). The

camshaft should rest on Tooling (A). Lifting of the
camshaft can cause misalignment as the camshaft
is removed, resulting in damage to the camshaft
bearings.
g01056675
Illustration 113
Typical example 9. Carefully slide the camshaft to the front of the
engine for removal. Use two people to remove
6. Remove Torx screws (9) and cover (10). Remove the camshaft. Keep the camshaft level while the
the O-ring seal from the cover. camshaft is being removed from the cylinder
head. The weight of camshaft (8) is approximately
39 kg (86 lb).
Note: Rotate the camshaft during removal. This will

prevent the camshaft from binding in the camshaft
bearings.
10. Remove Tooling (C) from the camshaft.
11. Remove Tooling (B) from front housing (7).
12. Remove Tooling (A) from the cylinder head.
g01287879
Illustration 114
58 KENR6232
i02554692
Camshaft - Install
Table 35
Required Tools
A GE50018 Cradle 1
B GE50017 Guide 1 g01286820
Illustration 116
C GE50015 Camshaft Pilot 2
D GE50025 Camshaft Hook 2 2. Install Tooling (A) on the cylinder head at Location
(Y).
H GE50016 Alignment Sleeve 1
POWERPART
J 21820221 1
Rubber Grease
POWERPART
K 21820117 Thread Lock and Nut 1
Lock
NOTICE

component life.
g01056901
NOTICE Illustration 117
Do not turn the crankshaft or the camshaft while the Typical example
not correctly timed during installation, interference can 3. Install Tooling (B) on front housing (7). Do not
occur between the pistons and the valves, resulting in tighten the bolts that hold Tooling (B) to front
damage to the engine. housing (7) at this time.
4. Use Tooling (H) to align Tooling (B) with the

NOTICE camshaft bearings. Tighten the bolts that hold
Care must be used when removing or installing the Tooling (B) to front housing (7). Remove Tooling
camshaft. Do not damage the finshed surfaces of the (H).
camshaft or the camshaft bearings.
Note: Tooling (H) should move freely from the bore
1. Ensure that the camshaft and camshaft bearings of Tooling (B).
are thoroughly clean. Lubricate the camshaft
bearings with clean engine oil.
KENR6232 59
g01293986
Illustration 118
Typical example
5. Install both Tooling (C) to the rear of camshaft (8).
6. Use two people to install the camshaft. Use

Tooling (D) to assist in aligning camshaft (8) Illustration 120
g01287358
with the camshaft bearings. Carefully slide the
camshaft into the cylinder head from the front of 11. Install O-ring seals (5) and (6) in sealing plate (3).
the engine. Keep the camshaft level while the Lubricate O-ring seal (5) with a Tooling (J).
camshaft is being installed in the cylinder head.
The weight of camshaft (8) is approximately 39 kg 12. Install adapter assembly (4) and sealing plate (3).
(86 lb). Ensure that the dowel in adapter assembly (4)
engages the hole in the camshaft.
Note: Rotate the camshaft during installation. This
will prevent the camshaft from binding in the camshaft Note: Ensure that the O-ring seal stays in the groove
bearings. in sealing plate (3).
7. Remove Tooling (C) when camshaft (8) is fully 13. Install thrust plate (1). Apply Tooling (K) to bolts
installed in the bore. (2). Hold the thrust plate in position and install
bolts (2). Evenly tighten bolts (2) to a torque of
8. Remove Tooling (A) from the cylinder head. 12 N·m (106 lb in).
9. Remove Tooling (B) from the front housing. Note: Ensure that the O-ring seal stays in the groove
in sealing plate (3).
14. Lubricate the camshaft lobes with clean engine

oil.
End By:
a. Install the camshaft gear. Refer to Disassembly

Install”.
b. Install the rocker arms and the rocker shafts.

Refer to Disassembly and Assembly, “Rocker
Arms and Shaft - Install”.
g01056675
Illustration 119
10. Install a new O-ring seal on cover (10). Position

the cover on the rear of the cylinder head. Install
torx screws (9) and tighten to a torque of 6 N·m
(53 lb in).
60 KENR6232
i02554695 1. Position the No. 1 piston at the top center of the

compression stroke. Refer to Systems Operation,
Camshaft Gear - Remove and Testing and Adjusting, “Finding Top Center
Install Position for No. 1 Piston”.
2. Verify that the timing mark on camshaft gear (1) is

aligned with Timing Mark (X) on front housing (3).
Removal Procedure
Table 36
Required Tools
A GE50019 Guide Stud 1
Start By:
a. Remove the front cover. Refer to Disassembly and

Assembly, “Front Cover - Remove”.
NOTICE g01286832
Illustration 122
3. Remove one bolt (2). Install Tooling (A).
component life. 4. Remove the remaining bolts (2) and remove
camshaft gear (1).
NOTICE
Do not turn the crankshaft or the camshaft while the Installation Procedure
Table 37
occur between the pistons and the valves, resulting in Required Tools
damage to the engine. Tool Part Number Part Description Qty
A GE50019 Guide Stud 1
NOTICE

component life.
NOTICE
g01286828
Illustration 121
KENR6232 61
g01286832 g00593987
Illustration 123 Illustration 125
Torque sequence for the camshaft gear
1. Align the hole in the back of camshaft gear (1) with
the dowel in the adapter. Position camshaft gear 4. Tighten the bolts for the camshaft gear in a
(1) onto Tooling (A) and install the camshaft gear. numeric sequence 1, 4, 2, 5, 3, 6, 1, 4 to a torque
of 240 N·m (180 lb ft).
5. Check the backlash between the camshaft gear

and the adjustable idler gear. The backlash should
be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer
to Systems Operation, Testing and Adjusting,
“Gear Group (Front) - Time” for the backlash
adjustment procedure.
End By:
a. Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Install”.
i02554694
Camshaft Bearings - Remove
Illustration 124
g01286828 Removal Procedure
Table 38
Note: Camshaft timing is critical. The timing mark on
the camshaft gear must be aligned with the timing Required Tools
mark on the front cover when the No. 1 piston is at Part
the top center of the compression stroke. Refer to Tool Number Part Description Qty
Systems Operation,Testing and Adjusting, “Gear
Group (Front) - Time”. Camshaft Bearing Tool
A 27610271 1
Group
2. Verify that the timing mark on camshaft gear (1) is 27610312 Camshaft Bearing Pilot 1
aligned with Timing Mark (X) on front housing (3). B Taperlock Stud
27610313 1
1/2 - 13 by 1 9/16 inch
Note: If the timing marks are not aligned, remove
camshaft gear (1) and rotate the camshaft until the C 27610314 Puller Plate 1
timing marks are aligned.
Start By:
3. Install bolts (2) finger tight. Remove Tooling (A)
and install the remaining bolt (2).
a. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”.
62 KENR6232
i02554693
NOTICE
Camshaft Bearings - Install
component life.
Table 39
Required Tools
Part
Camshaft Bearing Tool
A 27610271 1
Group
27610312 Camshaft Bearing Pilot 1
B Taperlock Stud
27610313 1
1/2 - 13 by 1 9/16 inch
C 27610314 Puller Plate 1
Illustration 126
g01159745 D 27610315 Alignment Bushing 1
27610316 Backup Plate 1
1. Remove the No. 7 camshaft bearing (rear). Work E
from the rear of the engine to the front of the Bolt
27610317 1
engine. 1/2 - 13 by 1 inch
F 27610318 Spacer Plate 1
2. Install the small end of Tooling (B) in camshaft
bearing (1).
NOTICE
3. Position Tooling (C) over Tooling (A). Install Keep all parts clean from contaminants.
Tooling (A) through the cylinder head on Tooling
(B). Contaminants may cause rapid wear and shortened
component life.
Note: Tooling (C) is installed on the outside of the
cylinder head. Tooling (C) is required in order to
remove all the camshaft bearings from the cylinder
head.
4. Use Tooling (A) to remove camshaft bearing (1)

from the cylinder head.
5. Remove Tooling (B) from Tooling (A) and remove

the camshaft bearing.
g01159754
Illustration 127
1. Install the No. 7 camshaft bearing (rear), as

follows:
a. Insert the large end of Tooling (B) into the No.

7 camshaft bore.
b. Position Tooling (C) over Tooling (A). Install

Tooling (A) through the cylinder head on
Tooling (B).
KENR6232 63
c. Position camshaft bearing (1) on Tooling (B).

Install Tooling (E) on Tooling (B).
Note: Refer to Specifications, “Cylinder Head” for

appropriate information for the orientation of the
camshaft bearings in the cylinder head.
d. Use Tooling (A) in order to pull camshaft

bearing (1) into the camshaft bore.
Note: When the chamfer of Tooling (E) contacts the

face of the camshaft bore, the camshaft bearing is
properly installed.
g01159758
Illustration 129
3. Install the No. 1 camshaft bearing (front), as

follows:
a. Insert the large end of Tooling (B) into the No.

1 camshaft bore. Assemble Tooling (A) and
Tooling (D) on Tooling (B).
b. Position camshaft bearing (1) on Tooling (B).

Install Tooling (E) and Tooling (F) on Tooling
(B).
Illustration 128
g01159756 Note: Refer to Specifications, “Cylinder Head” for
appropriate information for the location and the
2. Install the No. 6 through No. 2 camshaft bearings, orientation of the camshaft bearings in the cylinder
as follows: head.
a. Insert the large end of Tooling (B) into the Note: Tooling (F) is used to seat the No. 1 camshaft
camshaft bore. bearing to the correct depth in the camshaft bore.
Note: Use Tooling (D) to align Tooling (A) and Tooling c. Use Tooling (A) in order to pull the No. 1
(B) with the camshaft bearing bores. Install Tooling camshaft bearing into the No. 1 camshaft bore.
(D) in the inside diameter of any installed camshaft When the chamfer of Tooling (E) contacts
bearing between Tooling (A) and Tooling (B). the face of the camshaft bore, the camshaft
bearing is properly installed.
b. Install Tooling (A) on Tooling (B). Position
camshaft bearing (1) on Tooling (B). Install End By:
Tooling (E) on Tooling (B).
a. Install the camshaft. Refer to Disassembly and
Note: Refer to Specifications, “Cylinder Head” for Assembly, “Camshaft - Install”.
appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.
c. Use Tooling (A) in order to pull camshaft

bearing (1) into the camshaft bore.
Note: When the chamfer of Tooling (E) contacts the

face of the camshaft bore, the camshaft bearing is
properly installed.
64 KENR6232
i02554730
Engine Oil Pan - Remove and

Install
Removal Procedure
NOTICE

mandates.
NOTICE

component life.
g01284906
Illustration 130
Typical example
Hot oil and hot components can cause personal 2. Remove drain plug (3). Remove washer (2) from
injury. Do not allow hot oil or hot components to drain plug (3).
contact the skin.
3. Loosen bolts (5). Remove engine oil pan (4).
1. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and 4. Remove bolts (5) and seal (1) from engine oil pan
Maintenance Manual, “Engine Oil - Change”. (4).
Table 40
Required Tools
Part
A CH10888 Silicone Gasket 1
NOTICE

component life.
1. Clean the mating surfaces of the engine oil pan,

cylinder block, front housing, and the flywheel
housing.
KENR6232 65
3. Apply a bead of Tooling (A) to positions (X).
g01284984
Illustration 133
Tightening sequence
4. Install engine oil pan (4). Tighten bolts (5) in the

numerical sequence that is shown in Illustration
133. Tighten the bolts to a torque of 47 N·m
(35 lb ft).
5. Install a new washer (2) to drain plug (3). Install

drain plug (3) to engine oil pan (4). Tighten the
drain plug to a torque of 45 N·m (33 lb ft).
g01284906
Illustration 131 6. Fill the engine oil pan to the correct level. Refer to
Typical example Operation and Maintenance Manual, “Engine Oil
- Change”.
2. Install seal (1) and bolts (5) to engine oil pan (4).
i02554715
Cylinder Liner - Remove
Removal Procedure
Table 41
Required Tools
Part
Tool Part Description Qty
Number
A GE50001 Cylinder Liner Puller 1
Start By:
a. Remove the pistons and connecting rods. Refer

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

component life.
g01285214
Illustration 132
Typical example
66 KENR6232
1. Make temporary identification marks in order to

show the location of the cylinder liners.
g01111530
Illustration 135
Illustration 134
g01111472 2. Install liner seals (3) on cylinder liner (1).
2. Use Tooling (A) to remove cylinder liner (1). 3. Apply Tooling (C) on the cylinder block liner bore
surfaces and liner seals (3).
3. Remove liner seals (3) and filler band (2) from
cylinder liner (1). 4. Dip filler band (2) in clean engine oil for a
moment. Install the filler band on the cylinder liner
immediately.
i02554714
5. Use Tooling (B) to install cylinder liner (1) in the
Cylinder Liner - Install cylinder block. Ensure that any marks in relation
to the cylinder liner projection are in alignment.
End By:
a. Install the pistons and connecting rods. Refer
Table 42 to Disassembly and Assembly, “Pistons and
Required Tools Connecting Rods - Install”.
i02554770
B GE50000 Cylinder Liner Installer 1
POWERPART
Piston Cooling Jets - Remove
C 21820221 1
Rubber Grease and Install
NOTICE
Removal Procedure
component life. Table 43
Required Tools
Note: Ensure that the cylinder liners and the cylinder Tool Part Number Part Description Qty
block are clean and free from damage.
A CH11148 Engine Turning Tool 1
1. Check the cylinder liner projection. Refer to
Systems Operation, Testing and Adjusting, Start By:
“Cylinder Liner Projection - Inspect”.
a. Remove the engine oil pump. Refer to
Remove”.
KENR6232 67
2. Position piston cooling jet (2) in the cylinder block.

NOTICE Install bolt (1). Tighten the bolt to a torque of
Keep all parts clean from contaminants. 40 N·m (30 lb ft).
Contaminants may cause rapid wear and shortened Note: Ensure that the nozzles of the piston cooling
component life. jet are not damaged or distorted.
End By:
a. Install the engine oil pump. Refer to Disassembly

and Assembly, “Engine Oil Pump - Install”.
i02554775
Pistons and Connecting Rods

- Remove
Removal Procedure
g01103621
Illustration 136
Table 45
1. Use Tooling (A) to rotate the crankshaft in order to Required Tools
gain access to the piston cooling jet.
2. Remove bolt (1) and piston cooling jet (2). A CH11148 Engine Turning Tool 1
Installation Procedure Start By:

Table 44 a. Remove the cylinder head. Refer to Disassembly
Required Tools and Assembly, “Cylinder Head - Remove”.
Tool Part Number Part Description Qty b. Remove the engine oil pump. Refer to
A CH11148 Engine Turning Tool 1 Disassembly and Assembly, “Engine Oil Pump -
Remove”.
NOTICE c. Remove the piston cooling jets. Refer to

Keep all parts clean from contaminants. Disassembly and Assembly, “Piston Cooling Jets
- Remove and Install”.
component life. NOTICE

component life.
g01103621
Illustration 137
1. Use Tooling (A) to rotate the crankshaft in order to

gain access to the piston cooling jet.
68 KENR6232
i02554773

- Disassemble
Table 46
Required Tools
Part
g00998389
Illustration 138 A - Retaining Ring Pliers 1
1. Use Tooling (A) to rotate the crankshaft until the B - Piston Ring Expander 1
piston is at the bottom center.
Start By:
2. Remove the carbon ridge from the top inside
surface of the cylinder liner. a. Remove the pistons and connecting rods. Refer
3. Inspect the connecting rod and connecting rod cap Connecting Rods - Remove”.
for the proper identification mark. The connecting
rod and the connecting rod cap should have an Note: Mark the components of each piston and
etched number on the side. The number should connecting rod assembly. The components must be
match the cylinder number. Mark the connecting reinstalled in the original location. Do not interchange
rod and the connecting rod cap, if necessary. components.
Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly NOTICE
could cause the connecting rod to fracture. Keep all parts clean from contaminants.
4. Remove bolts (1) and connecting rod bearing cap Contaminants may cause rapid wear and shortened
(2). Push the connecting rod until the piston rings component life.
are out of the cylinder liner.
g00998390
Illustration 139
5. Remove piston (3) and the connecting rod from

the cylinder liner.
Note: Be careful not to damage the cylinder liner g01017728

Illustration 140
or the crankshaft journal during the removal of the
piston and the connecting rod.
KENR6232 69
1. Remove connecting rod bearing (9) from

connecting rod bearing cap (10). Remove
connecting rod bearing (9) from connecting rod
(6).
2. Use Tooling (A) to remove circlips (5) from piston

(4).
3. Remove piston pin (8) and connecting rod (6) from

piston (4).
4. Use Tooling (B) to remove piston rings (1), (2),

and (3) from piston (4).
5. Do not remove bearing (7) from connecting rod

(6).
i02554771

- Assemble Illustration 141
g01017728
2. Position the spring for oil control ring (3) in the oil
ring groove in piston (4).
Assembly Procedure
3. Position oil control ring (3) over the spring.
Table 47 Position the oil control ring so that the gap is 180
Required Tools degrees from the joint in the spring. Install the oil
control ring on the piston with Tooling (B).
Part
Tool Number Part Description Qty 4. Use Tooling (B) to install intermediate piston ring
A - Retaining Ring Pliers 1 (2) with the side that has the identification “UP-2”
toward the top of the piston.
B - Piston Ring Expander 1
5. Use Tooling (B) to install top piston ring (1) with
Note: Prior to removal from the engine, the pistons the side that has the identification “UP-1” toward
and connecting rod assemblies were marked. the top of the piston.
The components must be reassembled together.
The components must be installed in the original 6. Position piston rings (1), (2), and (3) so the gaps
location in the engine. Do not interchange any of the are 120 degrees from each other.
components.
7. Put piston (4) in position on connecting rod (6).
Apply clean engine oil to piston pin (8) and install
NOTICE piston pin (8). Install circlips (5) with Tooling (A).
Keep all parts clean from contaminants. Make sure that the circlips are fully seated in the
grooves of piston (4).
component life. 8. Install connecting rod bearings (9) in connecting
rod (6) and connecting rod cap (10). Make sure
1. Check the clearance between the ends of piston that rod bearings (9) are installed so that the
rings (1), (2), and (3). Refer to the Specifications bearing tabs fit into the notches in connecting rod
Manual, “Pistons And Rings” for the specifications. (6) and in connecting rod cap (10).
9. Ensure that the dowels are installed in connecting

rod cap (10) or in connecting rod (6).
End By:
a. Install the pistons and connecting rods. Refer

Connecting Rods - Install”.
70 KENR6232
i02554774 Note: Be careful not to damage the cylinder liner,

the crankshaft journal during installation of the piston
Pistons and Connecting Rods and the connecting rod.
- Install
3. Use Tooling (B) to install piston (3) and the
connecting rod in the cylinder liner. Ensure that the
connecting rod is seated on the crankshaft journal.
Installation Procedure Note: Install the connecting rod so that the bearing
tab is located on the side of the piston cooling jet.
Table 48
Ensure that the gaps for the piston rings are at 120
Required Tools degrees away from each other.
B GE50045 Piston Ring Compressor 1
C 21825607 Angle Gauge 1
NOTICE

component life.
Note: Install the connecting rod bearings dry g01016640

Illustration 143
when clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil on the connecting rod 4. Position connecting rod bearing cap (2) on the
bearings for final assembly. connecting rod.
1. Apply clean engine oil to the cylinder liner bore, Note: Ensure that the number on the side of the
to the piston rings, and to the outer surface of connecting rod bearing cap is on the same side as
the piston. the number on the connecting rod. The bearing tabs
of the connecting rod bearing cap and the connecting
Note: The piston and connecting rod are matched to rod are located on the side of the piston cooling jet.
a specific cylinder. Ensure that the connecting rod
and pistons are installed in the correct cylinder. 5. Lubricate the threads of bolts (1) with clean engine
oil. Install the bolts.
2. Use Tooling (A) to rotate the crankshaft until
the connecting rod journal is at the top center. 6. Use Tooling (A) to rotate the crankshaft until the
Lubricate the connecting rod bearings and the connecting rod journal is at the bottom center.
connecting rod journal with clean engine oil.
7. Tighten bolts (1), as follows:
a. Tighten Bolt (A) and Bolt (C) to a torque of

70 N·m (52 lb ft).
b. Tighten Bolt (B) and Bolt (D) to a torque of

70 N·m (52 lb ft).
c. Turn Bolt (B) and Bolt (D) for an additional 60

degrees (1/6 turn).
d. Tighten Bolt (A) and Bolt (C) to a torque of

70 N·m (52 lb ft).
e. Turn Bolt (A) and Bolt (C) for an additional 60

Illustration 142
g01048560 degrees (1/6 turn).
KENR6232 71
f. Ensure that the installed connecting rod

assembly has tactile side play. Carefully rotate
the crankshaft in order to ensure that there is
no binding.
End By:
a. Install the piston cooling jets. Refer to Disassembly

and Assembly, “Piston Cooling Jets - Remove
and Install”.
b. Install the engine oil pump. Refer to Disassembly

c. Install the cylinder head. Refer to Disassembly g00998459

and Assembly, “Cylinder Head - Install”. Illustration 144
1. Use Tooling (A) to rotate the crankshaft until the

i02554698 connecting rod is at the bottom center.
Connecting Rod Bearings - 2. Inspect the connecting rod and connecting rod cap
Remove for the proper identification mark. The connecting
rod and the connecting rod cap should have an
(Connecting rods in position) etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.
Removal Procedure Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly
Table 49 could cause the connecting rod to fracture.
Required Tools
3. Remove bolts (1) and connecting rod bearing cap
Part (2) from the connecting rod.
A CH11148 Engine Turning Tool 1 4. Remove the lower half of the connecting rod
bearing from the connecting rod bearing cap.
Start By: 5. Push the connecting rod away from the crankshaft.
Remove the upper half of the connecting rod
a. Remove the engine oil pump. Refer to bearing from the connecting rod.
Remove”.
i02554697
NOTICE
Connecting Rod Bearings -
Install
component life.
(Connecting rods in position)
Table 50
Required Tools
Part
B 21825607 Angle Gauge 1
72 KENR6232
NOTICE

component life.
Note: Install the connecting rod bearings dry

when clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil on the connecting rod
bearings for final assembly.
g01016640
Illustration 146
6. Position connecting rod bearing cap (2) on the

connecting rod.
Note: Ensure that the number on the side of the

connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs
rod are located on the side of the piston cooling jet.
7. Lubricate the threads of bolts (1) with clean engine

oil. Install the bolts.
g00998730
Illustration 145
8. Tighten bolts (1), as follows:
1. Use Tooling (A) to rotate the crankshaft until the
connecting rod journal is at the bottom center. a. Tighten Bolt (A) and Bolt (C) to a torque of
70 N·m (52 lb ft).
2. Install lower half connecting rod bearing (3) in
connecting rod bearing cap (2). Ensure that b. Tighten Bolt (B) and Bolt (D) to a torque of
bearing tab (4) is located in the notch of the 70 N·m (52 lb ft).
connecting rod bearing cap.
c. Turn Bolt (B) and Bolt (D) for an additional 60
3. Install the upper half connecting rod bearing in degrees (1/6 turn).
the connecting rod. Ensure that the bearing tab is
located in the notch of the connecting rod. d. Tighten Bolt (A) and Bolt (C) again to a torque
of 70 N·m (52 lb ft).
Note: The upper half connecting rod bearing has an
oil hole. e. Tighten Bolt (A) and Bolt (C) for an additional
60 degrees (1/6 turn).
4. Ensure that the dowels are installed in connecting
rod cap (2) or in the connecting rod. f. Ensure that the installed connecting rod
assembly has tactile side play. Carefully rotate
5. Pull the connecting rod onto the crankshaft. the crankshaft in order to ensure that there is
no binding.
End By:
a. Install the engine oil pump. Refer to Disassembly

KENR6232 73
i02554707
Crankshaft Main Bearings -

Remove
Removal Procedure
Table 51
Required Tools
A 27610319 Bearing Tool 1 g01020288
Illustration 148
Start By: 3. Install Tooling (A) in the oil hole of the crankshaft.
Carefully rotate the crankshaft in order to remove
a. Remove the engine oil pump. Refer to upper main bearing (3) from the cylinder block.
Remove”. Note: Push the upper main bearing from the opposite
side of the bearing tab with Tooling (A). If the
NOTICE crankshaft is turned in the wrong direction, the tab on
Keep all parts clean from contaminants. the bearing will be pushed between the crankshaft
and the bearing area of the cylinder block. This can
Contaminants may cause rapid wear and shortened result in damage to the cylinder block and/or the
component life. crankshaft.
1. Check the main bearing caps for identification of

the location and check the direction of the main
bearing caps in relation to the cylinder block. The
main bearing caps must be installed in the original
location and the original direction.
g01134355
Illustration 149
4. Remove thrust plates (4) from each side of the

No. 4 main bearing.
5. Remove the lower halves of the main bearings

g00996899
from the main bearing caps.
Illustration 147
2. Remove bolts (1) from No. 2 through No. 6 main

bearing caps (2).
Note: Remove No. 1 and No. 7 main bearing caps

(2) after No. 2 through No. 6 main bearing caps have
been installed.
74 KENR6232
i02554706 Note: Push the upper main bearing from the side of
the bearing tab with Tooling (A). If the crankshaft is
Crankshaft Main Bearings - turned in the wrong direction, the tab on the bearing
Install will be pushed between the crankshaft and the
bearing area of the cylinder block. This can result in
damage to the cylinder block and/or the crankshaft.
Table 52
Required Tools
A 27610319 Bearing Tool 1
B 21825617 Dial Indicator 1
C 21825607 Angle Gauge 1
NOTICE
Keep all parts clean from contaminants. Illustration 151
g01134355
Contaminants may cause rapid wear and shortened 2. Install thrust plates (4) on each side of the No. 4
component life. main bearing.
Note: Install the main bearings dry when clearance Note: Install the thrust plates with the words “Block
checks are performed. Refer to Disassembly and Side” toward the cylinder block.
Assembly, “Bearing Clearance - Check”. Apply clean
engine oil on the main bearings for final assembly. 3. Install the lower halves of the crankshaft main
bearings in the main bearing caps.
Note: Ensure that the main bearings are installed
so that bearing tabs fit into the notch in the cylinder Note: Ensure that the main bearings are installed so
block. The upper halves of the main bearings have that bearing tabs fit into the notch in the main bearing
the oil groove and the oil hole. caps.
g01018383
g01020300 Illustration 152
Illustration 150
1. Position upper main bearing (3) on the crankshaft. 4. Position main bearing caps (2) on the crankshaft.
Insert the end of the upper main bearing that
does not have the tab into the cylinder block. Note: Ensure that the numbers on the main bearing
Install Tooling (A) in the oil hole of the crankshaft. caps match the numbers on the cylinder block. Also
Carefully rotate the crankshaft in order to push the ensure that the “FRONT” on the main bearing cap is
upper main bearing into the cylinder block. When installed toward the front of the cylinder block.
the upper main bearing is flush with the cylinder
block, remove Tooling (A).
KENR6232 75
5. Lubricate the threads of bolts (1) with clean engine End By:
oil. Install the bolts to the main bearing caps.
Evenly tighten the bolts in order to pull the cap into a. Install the engine oil pump. Refer to Disassembly
position. Ensure that the cap is correctly seated. and Assembly, “Engine Oil Pump - Install”.
Note: Do not tap the cap into position as the bearing

i02554703
shell may be dislodged.
6. Tighten bolts (1) for the main bearing caps, as

Crankshaft - Remove
follows:
a. Tighten Bolt (A) to a torque of 258 N·m

(190 lb ft). Removal Procedure
Note: Bolt (A) is on the bearing tab side of the main Table 53
bearing cap. Required Tools
Part
b. Tighten Bolt (B) to a torque of 258 N·m
(190 lb ft).
- Bearing Puller 1
Note: Bolt (B) is on the opposite side of the bearing - Puller 1
tab of the main bearing cap. A
- Crossblock 1
c. Use Tooling (C) to tighten Bolt (B) for an - Puller Leg 2
additional 120 degrees (2 flats).
B - Dowel Extractor 1
d. Use Tooling (C) to tighten Bolt (A) for an
additional 120 degrees (2 flats).
Start By:
e. Rotate the crankshaft in order to ensure that
a. Remove the front housing. Refer to Disassembly
the crankshaft turns freely.
and Assembly, “Housing (Front) - Remove”.
b. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
c. Remove the piston cooling jets. Refer to

Disassembly and Assembly, “Piston Cooling Jets
NOTICE

component life.
1. Check the main bearing caps for identification for

the location and the direction in the cylinder block.
The identification marks on the main bearing caps
must be installed in the same direction prior to
removal.
g01253186
Illustration 153
Typical example
2. Check the connecting rod and the connecting rod
bearing caps for identification and the location in
7. Use Tooling (B) to check the crankshaft end play. the cylinder block.
Ensure that Tooling (B) is against a machined
surface. The end play is controlled by the thrust
plates of No. 4 main bearing (center).
Crankshaft end play (new thrust

plates) ....... 0.11 to 0.57 mm (0.004 to 0.022 inch)
76 KENR6232
7. Remove the thrust plates from each side of the

No. 4 main bearing.
8. Remove the lower main bearings from the main

bearing caps. Remove the upper main bearings
from the cylinder block.
Note: Mark the used main bearings or identify

the used main bearings for installation if the main
bearings will be used again.
g01017945
Illustration 154
3. Remove bolts (1) for connecting rod bearing cap

(2). Remove the connecting rod bearing caps.
g01289493
Illustration 157
9. Use Tooling (A) to remove crankshaft gear (6)

from crankshaft (5).
g01020310
Illustration 155
4. Remove bolts (3) for main bearing cap (4).

Remove the main bearing caps.
g01056151
Illustration 158
10. If necessary, use Tooling (B) to remove dowel (7)

and dowel (8) from crankshaft (5).
g01289487
Illustration 156
5. Install a suitable lifting device on each end of

crankshaft (5). The weight of crankshaft (5) is
approximately 177 kg (390 lb).
6. Remove the crankshaft from the cylinder block.
KENR6232 77
i02554702 4. Align the keyway in crankshaft gear (6) to dowel

(8) on the crankshaft . The Timing Mark “V” on the
Crankshaft - Install gear should face away from crankshaft (5).
5. Clean the cylinder block and the main bearing

caps thoroughly.
Table 54
Required Tools
Part
C 21825617 Dial Indicator Group 1
D 21825607 Angle Gauge 1
NOTICE
Contaminants may cause rapid wear and shortened Illustration 160

g01048335
component life.
Note: Install the main bearings dry when clearance
checks are performed. Refer to Disassembly and
Assembly, “Bearing Clearance - Check”. Apply clean
engine oil on the face of the main bearings for final
assembly.
6. Install the upper halves of main bearings (9) in

the cylinder block.
Note: Ensure that the main bearings are installed so

that the bearing tabs fit into the notch in the cylinder
block. The upper halves of the main bearings have
the oil groove and the oil hole.
7. Install a suitable lifting device to crankshaft (5).

g01018035
Illustration 159 The weight of crankshaft (5) is approximately
177 kg (390 lb).
1. If necessary, install dowel (7) in the crankshaft.
8. Install crankshaft (5) to the cylinder block.
Protrusion of dowel (7) from the crankshaft
face ........................................ 6.4 mm (0.25 inch)
2. If necessary, install dowel (8) in the crankshaft.
Protrusion of dowel (8) from the crankshaft

............................ 4.1 ± 0.5 mm (0.16 ± 0.02 inch)
Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or compo-
nents to contact your skin. Use protective clothing
or protective equipment to protect your skin.
g01048338
Illustration 161
3. The crankshaft gear is an interference fit on the
crankshaft. Heat crankshaft gear (6) in an oven 9. Install thrust plates (10) on each side of the No. 4
to 177 °C (350 °F). main bearing.
78 KENR6232
Note: Install the thrust plates with the words “Block d. Use Tooling (D) to tighten Bolt (A) through an
Side” toward the cylinder block. additional 120 degrees (2 flats).
10. Install the lower halves of the crankshaft main e. Rotate the crankshaft in order to ensure that
bearings in the main bearing caps. the crankshaft turns freely.
Note: Ensure that the main bearings are installed

so that the bearing tabs fit into the notch in the main
bearing cap.
g01020434
Illustration 162
11. Position main bearing caps (4) on the crankshaft. g01289529

Illustration 163
Note: Ensure that the numbers on the main bearing Typical example
caps match the numbers on the cylinder block. Also
ensure that the “FRONT” on the main bearing cap is 14. Use Tooling (C) to check the crankshaft end play.
installed toward the front of the cylinder block. Ensure that Tooling (C) is against a machined
surface. The end play is controlled by the thrust
12. Lubricate the threads of bolts (3) with clean plates of No. 4 main bearing (center).
engine oil. Install the bolts to the main bearing
caps. Evenly tighten the bolts in order to pull the Crankshaft end play (new thrust
cap into position. Ensure that the cap is correctly plates) ....... 0.11 to 0.57 mm (0.004 to 0.022 inch)
seated.
Note: Install the connecting rod bearings dry
Note: Do not tap the cap into position as the bearing when clearance checks are performed. Refer to
shell may be dislodged. Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil on the face of the
13. Tighten bolts (3) for the main bearing caps, as connecting rod bearings for final assembly.
follows:
a. Tighten Bolt (A) to a torque of 258 N·m

(190 lb ft).
Note: Bolt (A) is on the bearing tab side of the main

bearing cap.
b. Tighten Bolt (B) opposite the bearing tab side

Note: Bolt (B) is on the opposite side of the bearing

tab of the main bearing cap.
c. Use Tooling (D) to tighten Bolt (B) through an g01020428

additional 120 degrees (2 flats). Illustration 164
KENR6232 79
15. Position the connecting rod against the i02347769

crankshaft. Install connecting rod bearing cap (2)
on the connecting rod. Bearing Clearance - Check
Note: Ensure that the number on the side of the
connecting rod bearing cap is on the same side as
the number on the connecting rod. The bearing tabs Measurement Procedure
rod are located on the side of the piston cooling jet. Table 55
Required Tools
16. Lubricate the threads of bolts (1) with clean
engine oil. Install the bolts. Description Qty
Plastigauge (Green) 1
17. Tighten bolts (1), as follows: 0.025 to 0.076 mm
(0.001 to 0.003 inch)
a. Tighten Bolt (A) and Bolt (C) to a torque of
70 N·m (52 lb ft). Plastigauge (Red) 1
0.051 to 0.152 mm
(0.002 to 0.006 inch)
b. Tighten Bolt (B) and Bolt (D) to a torque of
70 N·m (52 lb ft). Plastigauge (Blue) 1
0.102 to 0.229 mm
c. Use Tooling (D) to turn Bolt (B) and Bolt (D) for (0.004 to 0.009 inch)
an additional 60 degrees (1/6 turn). Plastic Gauge (Yellow) 1
0.230 to 0.510 mm
d. Tighten Bolt (A) and Bolt (C) to a torque of (0.009 to 0.020 inch)
70 N·m (52 lb ft).
e. Use Tooling (D) to turn Bolt (A) and Bolt (C) for NOTICE
an additional 60 degrees (1/6 turn). Keep all parts clean from contaminants.
f. Ensure that the installed connecting rod Contaminants may cause rapid wear and shortened
assembly has tactile side play. Carefully rotate component life.
the crankshaft in order to ensure that there is
no binding.
Note: Perkins does not recommend the checking of
the actual clearances of the bearing shells particularly
End By:
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the
a. Install the piston cooling jets. Refer to Disassembly
bearing shell or the journal surfaces. Each Perkins
and Assembly, “Piston Cooling Jets - Remove
bearing shell is quality checked for specific wall
and Install”.
thickness. However, if the technician still wants to
measure the clearance of the bearing shell , the use
b. Install the flywheel housing. Refer to Disassembly
of Plastigauge is an acceptable method. Plastigauge
and Assembly, “Flywheel Housing - Remove and
is less accurate on journals with small diameters if
Install”.
clearances are less than 0.10 mm (0.004 inch).
c. Install the front housing. Refer to Disassembly and
Note: The bearing clearance for the crankshaft
Assembly, “Housing (Front) - Install”.
should be within specifications if the crankshaft
journals and the crankshaft pins were checked before
installing the crankshaft and the correct bearing shells
are installed. No further checks should be necessary.
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
The technician must be very careful to use

Plastigauge correctly. The following points must be
observed:
• Ensure that the backs of the bearing shells and the

bores of the bearing shells are clean and dry.
80 KENR6232
• If the bearing shells have locating tabs ensure that Note: When Plastigauge is used, the readings can
the locating tabs are properly seated in the tab sometimes be unclear. For example, all parts of the
grooves. Plastigauge are not the same width. Measure the
major width in order to ensure that the parts are within
• The crankshaft must be clean and free of oil at the the specification range. Refer to the Specifications
contact points of the Plastigauge. Manual, “Connecting Rod Bearing Journal” and refer
to the Specifications Manual, “Main Bearing Journal”
for the correct clearances.
i02554686
Atmospheric Pressure Sensor

- Remove and Install
Removal Procedure
NOTICE

component life.
g01010832
Illustration 165
Typical example
1. Place a piece of the Plastigauge (1) onto the

crown of the bearing shell that is in the cap.
Note: Do not allow the Plastigauge (1) to extend over

the edge of the bearing shell.
2. Use the correct torque-turn specifications in order

to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
shell when the cap is installed. Illustration 166
g01281274
Note: Do not turn the crankshaft when the 1. Slide the locking tab into the unlocked position.
Plastigauge (1) is installed. Disconnect harness assembly (1) from
atmospheric pressure sensor (2).
3. Carefully remove the bearing cap, but do not
remove the Plastigauge (1). Measure the width of 2. Remove atmospheric pressure sensor (2) from
the Plastigauge (1) while the Plastigauge is in the the adapter on the cylinder block.
bearing cap or on the crankshaft journal. Refer
to the Illustration 165. 3. Remove the O-ring seal from atmospheric
pressure sensor (2).
4. Remove all of the Plastigauge (1) before you
install the bearing cap.
KENR6232 81
Table 56 Camshaft Position Sensor -

Required Tools Remove and Install
Part
Number
POWERPART
A 21820221
Rubber Grease
1 Removal Procedure
NOTICE
NOTICE Care must be taken to ensure that fluids are contained
Keep all parts clean from contaminants. during performance of inspection, maintenance, test-
Contaminants may cause rapid wear and shortened collect the fluid with suitable containers before open-
component life. ing any compartment or disassembling any compo-

mandates.
NOTICE

component life.
g01281274
Illustration 167
1. Install a new O-ring seal to atmospheric pressure

sensor (2). Lubricate the O-ring seal with Tooling
(A).
2. Use a deep socket to install atmospheric pressure

sensor (2) to the adapter on the cylinder block.
Tighten the atmospheric pressure sensor to a
torque of 10 N·m (89 lb in).
3. Connect harness assembly (1) to atmospheric

pressure sensor (2). Slide the locking tab into the
locked position.
g01281454
Illustration 168
1. Slide the locking tab into the unlocked position.

Disconnect harness assembly (4).
2. Remove bolt (3). Carefully remove camshaft

position sensor (1) from adapter (2).
Note: Do not use a lever to remove the camshaft

position sensor from the adapter.
3. Remove the O-ring seal from camshaft position

sensor (1).
82 KENR6232
Table 57 Crankshaft Position Sensor -

Part
Number
POWERPART
A 21820221
Rubber Grease
1 Removal Procedure
NOTICE

mandates.
NOTICE

component life.
g01281454
Illustration 169
1. Install a new O-ring seal to the camshaft position

(A).
2. Position camshaft position sensor (1) into adapter

(2) and install bolt (3). Tighten the bolt to a torque
of 25 N·m (18 lb ft).
3. Connect harness assembly (4). Slide the locking

g01281746
tab into the locked position. Illustration 170

Disconnect harness assembly (3). Cut the cable
tie that secures the sensor wire.
2. Remove bolt (2) that fastens crankshaft position

sensor (1) to the front housing. Carefully remove
the crankshaft position sensor.
3. Remove the O-ring seal from the crankshaft

position sensor (1).
KENR6232 83
Table 58 Coolant Temperature Sensor -

Part
Number
POWERPART
A 21820221
Rubber Grease
1 Removal Procedure
NOTICE

mandates.
NOTICE

component life.
1. Drain the coolant from the cooling system to a

level below the coolant temperature sensor into a
suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change”.
g01281746
Illustration 171
1. Install a new O-ring seal on the crankshaft position

(A).
2. Install crankshaft position sensor (1) into the front

housing. Install bolt (2). Tighten the bolt to a
3. Connect harness assembly (3). Slide the locking

tab into the locked position. Use a new cable tie in
order to secure the sensor wire.
g01282657
Illustration 172

Disconnect the harness assembly from coolant
84 KENR6232
3. Use a deep socket in order to remove coolant 4. Fill the cooling system with coolant. Refer to
temperature sensor (1) from the water temperature Operation and Maintenance Manual, “Cooling
regulator housing. System Coolant - Change”.
4. Remove the O-ring seal from the coolant

i02554731
temperature sensor.
Engine Oil Pressure Sensor -
Installation Procedure Remove and Install
Table 59
Required Tools
Tool
Part
Part Description Qty Removal Procedure
Number
A 21820221
POWERPART
1
NOTICE
Rubber Grease Care must be taken to ensure that fluids are contained
NOTICE collect the fluid with suitable containers before open-
Keep all parts clean from contaminants. ing any compartment or disassembling any compo-
component life. Dispose of all fluids according to local regulations and
mandates.
NOTICE

component life.
g01282657
Illustration 173
g01281335
Illustration 174
1. Install a new O-ring seal on the coolant
temperature sensor. Lubricate the O-ring seal with
Tooling (A).
Disconnect harness assembly (1) from engine oil
2. Install coolant temperature sensor (1) to the water
temperature regulator housing. Use a deep socket
2. Remove engine oil pressure sensor (2) from
to tighten the coolant temperature sensor to a
adapter (3).
3. Remove the O-ring seal from adapter (3).
3. Connect the harness assembly to coolant
KENR6232 85
Table 60 Fuel Temperature Sensor -

Part
Number
POWERPART
A 21820221
Rubber Grease
1 Removal Procedure
NOTICE

mandates.
NOTICE

component life.
g01281335
Illustration 175
1. Lubricate a new O-ring seal with Tooling (A).

Install the O-ring seal to adapter (3).
2. Install engine oil pressure sensor (2) to adapter

(3). Tighten the engine oil pressure sensor to a
torque of 10 N·m (89 lb in).
3. Connect harness assembly (1) to engine oil

g01281748
locked position. Illustration 176

Disconnect the harness assembly from fuel
2. Use a deep socket in order to remove fuel

temperature sensor (1) from the fuel filter base.
3. Remove the O-ring seal from the fuel temperature

sensor.
86 KENR6232
Table 61
Required Tools
Part
Number
POWERPART
A 21820221 1
Rubber Grease
NOTICE

component life.
g01282129
Illustration 178

Disconnect the harness assembly from inlet
manifold temperature sensor (1).
2. Use a deep socket to remove inlet manifold

temperature sensor (1) from the cylinder head.
3. Remove the O-ring seal from inlet manifold

g01281748
Illustration 177 temperature sensor (1).
1. Install a new O-ring seal to fuel temperature

sensor (1). Lubricate the O-ring seal with Tooling Installation Procedure
(A). Table 62
2. Install fuel temperature sensor (1) to the fuel Required Tools

filter base. Use a deep socket to tighten the fuel Part
temperature sensor to a torque of 20 N·m (15 lb ft). Tool Part Description Qty
Number
3. Connect the harness assembly to fuel temperature POWERPART

A 21820221 1
sensor (1). Slide the locking tab into the locked Rubber Grease
position.
NOTICE
i02554252 Keep all parts clean from contaminants.
Inlet Manifold Temperature Contaminants may cause rapid wear and shortened
component life.
Sensor - Remove and Install
Removal Procedure
NOTICE

component life.
KENR6232 87
g01282129 g01281749
Typical example
1. Install a new O-ring seal to inlet manifold Disconnect the harness assembly from inlet
temperature sensor (1). Lubricate the O-ring seal manifold pressure sensor (1).
with Tooling (A).
2. Use a deep socket to remove inlet manifold
2. Use a deep socket to install inlet manifold pressure sensor (1) from the adapter in the
temperature sensor (1) to the cylinder head. cylinder head.
Tighten the inlet manifold temperature sensor to a
torque of 20 N·m (15 lb ft). 3. Remove the O-ring seal from inlet manifold
temperature sensor (1). Slide the locking tab into Installation Procedure
Table 63
i02554255 Required Tools
Inlet Manifold Pressure Sensor Tool

Part
Number
Part Description Qty
- Remove and Install POWERPART
A 21820221 1
Rubber Grease
Removal Procedure NOTICE

NOTICE Contaminants may cause rapid wear and shortened
Keep all parts clean from contaminants. component life.
component life.
88 KENR6232
g01281749 g01285642
Typical example
1. Loosen nut (1).
1. Install a new O-ring seal to inlet manifold pressure
sensor (1). Lubricate the O-ring seal with Tooling 2. Rotate bolt (2) in order to release the tension on
(A). the V-belts. Remove the V-belts from the pulley of
belt tightener (3).
2. Use a deep socket to install inlet manifold
pressure sensor (1) to the adapter in the cylinder 3. Remove bolts (4) and remove belt tightener (3).
head. Tighten the inlet manifold pressure sensor
to a torque of 10 N·m (89 lb in).

locked position.
i02554690
Belt Tightener - Remove
Removal Procedure
Start By:
a. Remove the alternator. Refer to Disassembly and

Assembly, “Alternator - Remove and Install”.
KENR6232 89
i02554689 i02582917
Belt Tightener - Install Fan - Remove and Install
Installation Procedure Removal Procedure
g01285642 g01294064
Typical example
1. Position belt tightener (3) and install bolts (4).
Tighten the bolts to a torque of 47 N·m (35 lb ft). 1. Remove the engine fan guards.
2. Install the V-belts on the pulley of belt tightener (3). 2. Remove bolts (1).
3. Rotate bolt (2) in order to adjust the tension of Note: Ensure that the radiator is protected during
the V-belts. Refer to Operation and Maintenance removal of the fan assembly.
Manual, “Belt Tension Chart”.
3. Remove fan (3) and adapter (2) as a assembly.
4. Tighten nut (1).
4. If necessary, remove fan (3) from adapter (2).
End By: Note the orientation of fan.
a. Install the alternator. Refer to Disassembly and

Assembly, “Alternator - Remove and Install”. Installation Procedure
1. Ensure that all the components are free damage.
If necessary, replace any components that are
damaged.
90 KENR6232
g01294064 g01285717
Typical example
2. Loosen nut (1). Rotate bolt (2) in order to release
2. If necessary, install fan (3) to adapter (2). Ensure the tension on the V-belts.
that the fan is correctly oriented. Install bolts (4)
and tighten to a torque of 47 N·m (35 lb ft).
3. Install the assembly of the fan and the adapter.
Note: Ensure that the radiator is protected during

installation of the fan assembly.
4. Install bolts (1). Tighten bolts (1) to a torque of

47 N·m (35 lb ft).
5. Install the engine fan guards.
i02554743
Fan Drive - Remove
Removal Procedure
g01285650
Illustration 187
Start By:
3. Remove the V-belts from the pulley of fan drive
a. Remove the fan. Refer to Disassembly and (3).
4. Attach a suitable lifting strap to the assembly of fan
1. Remove the V-belt from the alternator pulley. drive (3). Support the weight of the fan drive. The
Refer to Disassembly and Assembly, “Alternator - assembly of the fan drive weighs approximately
Remove and Install” for the correct procedure. 17 kg (37 lb).
5. Remove nuts and washers (4) from the assembly

of fan drive (3).
KENR6232 91
6. Use the lifting strap in order to remove the

assembly of the drive (3).
i02554740
Fan Drive - Install
g01285717
Illustration 189
4. Position the V-belts on the pulley of fan drive (3)

and the pulley of the belt tightener.
5. Rotate bolt (2) in order to adjust the tension of the

V-belts. Refer to Systems Operation, Test and
Adjusting , “Belt Tension Chart”.
6. Tighten nut (1).

g01285650
Illustration 188 7. Install the V-belt to the alternator pulley. Refer to
Disassembly and Assembly, “Alternator - Remove
1. Use a suitable lifting strap in order to position the and Install” for the correct procedure.
assembly of fan drive (3) on the front housing. The
assembly of the fan drive weighs approximately End By:
17 kg (37 lb).
a. Install the fan. Refer to Disassembly and
2. Install washers and nuts (4). Tighten the nuts to a Assembly, “Fan - Remove and Install”.
3. Remove the lifting strap. i02554779
Pump Drive - Remove

(Transfer pump)
Removal Procedure
Start By:
a. Remove the fuel transfer pump. Refer to

Disassembly and Assembly, “Fuel Transfer Pump
- Remove”.
92 KENR6232
i02554777
NOTICE
Pump Drive - Disassemble
during performance of inspection, maintenance, test- (Transfer pump)
Dispose of all fluids according to local regulations and Table 64
mandates.
Required Tools
NOTICE Part
Number
A - Retaining Ring Pliers 1
- Bearing Puller 1
component life.
- Puller 1
B
- Crossblock 1
- Puller Leg 2
Start By:
a. Remove the pump drive. Refer to Disassembly

and Assembly, “Pump Drive - Remove”.
NOTICE

Illustration 190
g01280964 component life.
1. Remove bolts (2).
2. Use a soft hammer in order to remove assembly of

pump drive (3) from front housing (1). Remove the
O-ring seal from the assembly of the pump drive.
g01050307
Illustration 191
1. Remove bolts (3) and washers (4) that secure

adapter (7) to bearing (6).
KENR6232 93
2. Place the pump drive onto a suitable support. 2. Place the gear shaft on a suitable support. Press
Press the assembly of gear (2) and bearings (1) on the inner race of bearing (1) until the bearing
and (6) out of adapter (7). is against gear (2).
3. Use Tooling (A) to remove retaining ring (5). 3. Place the inner race of bearing (6) onto a suitable
support. Press the shaft of gear (2) into bearing
4. Use Tooling (B) or use a suitable press in order to (6) until the shoulder on the gear is against the
remove bearings (1) and (6) from gear (2). bearing.
4. Use Tooling (A) to install retaining ring (5).

i02554776
Pump Drive - Assemble 5. Place adapter (7) on a suitable support. Press the
assembly of the gear and the bearings into the
(Transfer pump) adapter. Ensure that bearing (6) is against the
front face of the recess in adapter (7).
6. Install bolts (3) and washers (4). Tighten the bolts

Assembly Procedure to a torque of 12 N·m (105 lb in).
Table 65 End By:

Required Tools a. Install the pump drive. Refer to Disassembly and
Part Assembly, “Pump Drive - Install”.
A - Retaining Ring Pliers 1 i02554778
Pump Drive - Install

NOTICE
Keep all parts clean from contaminants. (Transfer pump)
component life.
1. Inspect the condition of the teeth and the splines
of gear (2) for wear or damage. Inspect bearings NOTICE
(1) and (6), retaining ring (5), and adapter (7) for Keep all parts clean from contaminants.
wear or damage. Replace any components that
are worn or damaged. Contaminants may cause rapid wear and shortened
component life.
g01280964
Illustration 193
1. Install a new O-ring seal to the assembly of pump

drive (3).
Illustration 192
g01050307 2. Install the assembly of pump drive (3) to front
housing (1).
94 KENR6232
3. Install bolts (2). Tighten the bolts to a torque of 6. If necessary, remove the brackets that support
47 N·m (35 lb ft). the harness assemblies.
Note: The bolts are different lengths. Ensure that the

bolts are installed in the correct position.
1. If a replacement electronic control module is
End By:
installed, the module must be programmed with
the correct information. Refer to Troubleshooting,
a. Install the fuel transfer pump. Refer to Disassembly
“Replacing the ECM” and refer to Troubleshooting,
and Assembly, “Fuel Transfer Pump - Install”.
“Flash Programming” for the correct procedure.
i02554718 2. If necessary, install the brackets that support the

wiring harnesses.
Electronic Control Module -
Remove and Install
Removal Procedure
1. Disconnect the negative battery terminal at the
battery.
g01281217
Illustration 195
3. Install isolation mounts and spacers (9) to

electronic control module (10). Install washers and
bolts (8) to electronic control module (10). Ensure
that ground strap (7) for the electronic control
module is clamped between the washer and the
appropriate bolt.
4. Install the assembly of the electronic control

g01281217
Illustration 194 module. Tighten bolts (8) to a torque of 25 N·m
(18 lb ft).
2. Remove nuts (6). Loosen allen head screw (4).
Disconnect the OEM harness (5) from electronic Note: Ensure that the ground strap is not strained
control module (10). as the bolt is tightened.
3. Cut cable tie (3). Loosen allen head screw (1). 5. Connect engine wiring harness (2) to electronic
Disconnect engine harness assembly (2) from control module (10). Tighten allen head screw (1)
electronic control module (10). to a torque of 5 N·m (44 lb in).
4. Remove bolts (8) and remove the assembly of Note: Care must be taken in order to avoid damage to
electronic control module (10). Note the position the connector pins during installation of the harness.
of any brackets that are secured by the bolts.
6. Position engine wiring harness (2) against the
5. Remove washers and the isolation mounts (9) support bracket. Use a new cable tie (3), in order
from the electronic control module. to secure the engine wiring harness to the bracket.
KENR6232 95
7. Connect OEM wiring harness (5) to electronic 3. Disconnect the wiring harness assembly from
control module (10). Tighten allen head screw (4) alternator (5).
to a torque of 5 N·m (44 lb in).
4. Loosen bolt (1) and nut (6). Loosen the bolt for
Note: Care must be taken in order to avoid damage to link (3). Push the alternator toward the engine.
the connector pins during installation of the harness. Remove the V-belt from the alternator pulley.
8. Position OEM wiring harness (5) against the 5. Remove bolt (1), washer (2) and spacer (4) from
support bracket. Install nuts (6) in order to secure alternator (5).
OEM wiring harness (5) to the bracket.
6. Remove nut (6) and washer (7). Remove bolt (8),
9. Connect the negative battery terminal at the washer (10) and spacer (9) from alternator (5).
battery. Remove the alternator.
i02554685 Installation Procedure

Alternator - Remove and Install
Removal Procedure
Personal injury can result from failure to discon-

nect the battery.
First, disconnect the negative battery cable. Then,

disconnect the positive battery cable.
A positive power lead can cause sparks if the bat-

tery is not disconnected. Sparks can possibly re-
sult in battery explosion or fire.
1. Disconnect the battery.

g01282673
Illustration 197
2. Place identification marks on all of the wiring
harness connections. 1. Put alternator (5) in position and install bolt (8),
washer (10) and spacer (9). Install nut (6) and
washer (7) finger tight.
2. Put link (3) into position on the alternator and

loosely install bolt (1), washer (2) and spacer (4) .
3. Install the V-belt. Tension the V-belt. Refer to

Systems Operation, Testing and Adjusting, “Belt
Tension Chart”.
4. Tighten bolt (1) to a torque of 70 N·m (52 lb ft).

Tighten nut (6) to a torque of 105 N·m (77 lb ft).
Tighten the bolt for link (3) to a torque of 105 N·m
(77 lb ft).
5. Connect the harness assemblies to the alternator.

Refer to Specifications, “Alternator” for the torque
values.
6. Connect the battery.
g01282673
Illustration 196
Typical Example
96 KENR6232
i02554716 5. Attach a suitable lifting device to electric starting

motor (2). The weight of electric starting motor is
Electric Starting Motor - approximately 26.5 kg (58.4 lb).
Remove and Install
6. Remove bolts (3). Remove electric starting motor
(2) from the flywheel housing.
Removal Procedure Installation Procedure

NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
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
disconnected battery cable end in order to prevent
contact with other metal surfaces which could ac-
tivate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch

g01281213
location to inform personnel that the equipment is Illustration 199
being worked on.
1. Attach a suitable lifting device to electric starting
motor (2). The weight of electric starting motor is
1. Disconnect the batteries.
approximately 26.5 kg (58.4 lb).
2. Put an identification mark on the harness
2. Position electric starting motor (2) on the flywheel
assemblies that are connected to the electric
housing. Install bolts (3). Tighten the bolts to a
starting motor and the solenoid.
torque of 215 N·m (160 lb ft). Remove the lifting
device from the electric starting motor.
3. Connect the harness assemblies to solenoid (1).

Tighten the nuts. Refer to Specifications, “Electric
Starting Motor” for the correct torque values.
4. Connect the harness assemblies to electric

starting motor (2). Tighten the nuts. Refer to
Specifications, “Electric Starting Motor” for the
correct torque value.
5. Connect the batteries.
g01281213
Illustration 198
3. Disconnect the harness assemblies from solenoid

(1).
4. Disconnect the harness assembly from electric

starting motor (2).
KENR6232 97
Index Section
Index
A Crankshaft Main Bearings - Install......................... 74
Installation Procedure ........................................ 74
Alternator - Remove and Install ............................. 95 Crankshaft Main Bearings - Remove..................... 73
Installation Procedure ........................................ 95 Removal Procedure ........................................... 73
Removal Procedure ........................................... 95 Crankshaft Position Sensor - Remove and Install.. 82
Atmospheric Pressure Sensor - Remove and Installation Procedure ........................................ 83
Install ................................................................... 80 Removal Procedure ........................................... 82
Installation Procedure ........................................ 81 Crankshaft Rear Seal - Install................................ 34
Removal Procedure ........................................... 80 Installation Procedure ........................................ 34
Crankshaft Rear Seal - Remove............................ 33
Removal Procedure ........................................... 33
B Cylinder Head - Install ........................................... 53
Bearing Clearance - Check ................................... 79 Cylinder Head - Remove ....................................... 51
Measurement Procedure ................................... 79 Removal Procedure ........................................... 51
Belt Tightener - Install............................................ 89 Cylinder Liner - Install............................................ 66
Installation Procedure ........................................ 89 Installation Procedure ........................................ 66
Belt Tightener - Remove........................................ 88 Cylinder Liner - Remove........................................ 65
Removal Procedure ........................................... 88 Removal Procedure ........................................... 65
C D
Camshaft - Install................................................... 58 Disassembly and Assembly Section...................... 4

Camshaft - Remove............................................... 56
Removal Procedure ........................................... 56 E
Camshaft Bearings - Install ................................... 62
Installation Procedure ........................................ 62 Electric Starting Motor - Remove and Install ......... 96
Camshaft Bearings - Remove ............................... 61 Installation Procedure ........................................ 96
Camshaft Gear - Remove and Install .................... 60 Electronic Control Module - Remove and Install ... 94
Camshaft Position Sensor - Remove and Install ... 81 Electronic Unit Injector - Install .............................. 9
Removal Procedure ........................................... 81 Electronic Unit Injector - Remove .......................... 8
Connecting Rod Bearings - Install (Connecting rods Removal Procedure ........................................... 8
in position) ........................................................... 71 Electronic Unit Injector Sleeve - Install .................. 11
Connecting Rod Bearings - Remove (Connecting Electronic Unit Injector Sleeve - Remove .............. 10
rods in position) ................................................... 71 Removal Procedure ........................................... 10
Removal Procedure ........................................... 71 Engine Oil Cooler - Install...................................... 23
Coolant Temperature Sensor - Remove and Installation Procedure ........................................ 23
Install ................................................................... 83 Engine Oil Cooler - Remove.................................. 23
Removal Procedure ........................................... 83 Engine Oil Filter Base - Assemble......................... 21
Crankcase Breather - Remove and Install (Open Assembly Procedure.......................................... 21
Breather).............................................................. 47 Engine Oil Filter Base - Disassemble .................... 21
Installation Procedure ........................................ 47 Disassembly Procedure ..................................... 21
Removal Procedure ........................................... 47 Engine Oil Filter Base - Install ............................... 22
Crankshaft - Install................................................. 77 Installation Procedure ........................................ 22
Installation Procedure ........................................ 77 Engine Oil Filter Base - Remove ........................... 20
Crankshaft - Remove............................................. 75 Removal Procedure ........................................... 20
Removal Procedure ........................................... 75 Engine Oil Pan - Remove and Install..................... 64
Crankshaft Front Seal - Install ............................... 39 Installation Procedure ........................................ 64
Crankshaft Front Seal - Remove ........................... 38 Engine Oil Pressure Sensor - Remove and Install.. 84
Removal Procedure ........................................... 38 Installation Procedure ........................................ 85
98 KENR6232
Index Section
Engine Oil Pump - Assemble................................. 25 G

Assembly Procedure.......................................... 25
Engine Oil Pump - Disassemble............................ 24 Gear Group (Front) - Install ................................... 43
Disassembly Procedure ..................................... 24 Installation Procedure ........................................ 43
Engine Oil Pump - Install ....................................... 26 Gear Group (Front) - Remove ............................... 41
Engine Oil Pump - Remove ................................... 24
Engine Support (Front) - Remove and Install ........ 30 H
Removal Procedure ........................................... 30 Housing (Front) - Install ......................................... 46
Exhaust Elbow - Remove and Install..................... 15 Installation Procedure ........................................ 46
Installation Procedures ...................................... 15 Housing (Front) - Remove ..................................... 45
Exhaust Manifold - Remove and Install ................. 14
Removal Procedure ........................................... 14 I
Important Safety Information ................................. 2

F Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 19
Fan - Remove and Install ...................................... 89 Installation Procedure ........................................ 20
Removal Procedure ........................................... 89 Inlet and Exhaust Valve Springs - Remove and
Fan Drive - Install .................................................. 91 Install ................................................................... 15
Fan Drive - Remove .............................................. 90 Removal Procedure ........................................... 15
Removal Procedure ........................................... 90 Inlet and Exhaust Valves - Remove and Install ..... 17
Flywheel - Install.................................................... 32 Installation Procedure ........................................ 18
Flywheel - Remove................................................ 31 Inlet Manifold Pressure Sensor - Remove and
Removal Procedure ........................................... 31 Install ................................................................... 87
Flywheel Housing - Remove and Install ................ 34 Installation Procedure ........................................ 87
Removal Procedure ........................................... 34 Inlet Manifold Temperature Sensor - Remove and
Front Cover - Install ............................................... 41 Install ................................................................... 86
Front Cover - Remove ........................................... 40 Removal Procedure ........................................... 86
Fuel Filter Base - Assemble .................................. 6
Assembly Procedure.......................................... 6 P
Fuel Filter Base - Disassemble.............................. 5
Disassembly Procedure ..................................... 5 Piston Cooling Jets - Remove and Install.............. 66
Fuel Filter Base - Install......................................... 6 Installation Procedure ........................................ 67
Fuel Filter Base - Remove..................................... 4 Pistons and Connecting Rods - Assemble ............ 69
Removal Procedure ........................................... 4 Assembly Procedure.......................................... 69
Fuel Priming Pump - Remove and Install .............. 4 Pistons and Connecting Rods - Disassemble ....... 68
Installation Procedure ........................................ 4 Disassembly Procedure ..................................... 68
Removal Procedure ........................................... 4 Pistons and Connecting Rods - Install................... 70
Fuel Temperature Sensor - Remove and Install .... 85 Installation Procedure ........................................ 70
Installation Procedure ........................................ 86 Pistons and Connecting Rods - Remove............... 67
Fuel Transfer Pump - Install .................................. 7 Pump Drive - Assemble (Transfer pump) .............. 93
Installation Procedure ........................................ 7 Assembly Procedure.......................................... 93
Fuel Transfer Pump - Remove .............................. 7 Pump Drive - Disassemble (Transfer pump) ......... 92
Removal Procedure ........................................... 7 Disassembly Procedure ..................................... 92
Pump Drive - Install (Transfer pump) .................... 93
Pump Drive - Remove (Transfer pump) ................ 91
KENR6232 99
Index Section
Rocker Arm - Assemble......................................... 50

Assembly Procedure.......................................... 50
Rocker Arm - Disassemble.................................... 49
Disassembly Procedure ..................................... 49
Rocker Arm and Shaft - Install............................... 51
Rocker Arm and Shaft - Remove........................... 49
Table of Contents................................................... 3
Turbocharger - Install ............................................ 13
Turbocharger - Remove ........................................ 12
Valve Mechanism Cover - Remove and Install...... 48

Vibration Damper and Pulley - Remove and
Install ................................................................... 36
Water Pump - Install .............................................. 28

Water Pump - Remove .......................................... 27
Water Temperature Regulator Housing - Remove and
Install ................................................................... 28
Copyright ©2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K .

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The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Cylinder Head - Remove ...................................... 51

Disassembly and Assembly Installation Procedure

4. Remove the air from the system. Refer to Systems

Fuel Filter Base - Remove

Dispose of all fluids according to local regulations and

a. Remove the fuel filter base. Refer to Disassembly

Contaminants may cause rapid wear and shortened

2. Place a suitable container below the fuel filter

6. Remove plugs (9), (11) and (12) from fuel filter

i02554752 6. Install fuel temperature sensor (2) to fuel filter

7. Install fuel priming pump (4) to fuel filter

Contaminants may cause rapid wear and shortened

2. Install new O-ring seals to plugs (9), (11) and (12).

3. Install new O-ring seals to connections (3), (5), (7)

Note: Ensure correct orientation of the connections.

4. Install new O-ring seals to fuel bypass valve (6).

Install new O-ring seals to plugs (9) and (11).

Refer to Operation and Maintenance Manual,

3. Connect hose assemblies (3), (5), (7) and (8).

4. Connect harness assembly (1) to fuel temperature

5. Turn the fuel supply to the “ON” position.

i02554761 4. Remove bolts (4) and remove fuel transfer pump

Removal Procedure i02554849

NOTICE Fuel Transfer Pump - Install

1. Turn the fuel supply to the “OFF” position.

2. Place a suitable container below the fuel transfer

2. Lubricate a new O-ring seal with clean engine oil.

3. Position fuel transfer pump (1) on pump drive (5).

Note: Ensure that the splines on the shaft of the fuel

4. Install bolts (4). Tighten the bolts to a torque of

5. Remove the plugs from the hose assemblies.

6. Turn the fuel supply to the “ON” position.

i02554720 3. Remove valve bridges (3).

a. Remove the rocker arms and the rocker arm shaft.

Electronic Unit Injector - Install

Contaminants may cause rapid wear and shortened

1. Use Tooling (D) to clean the carbon deposit from

2. Use Tooling (B) to remove the fuel and oil from

3. Ensure that seat area (X) on the electronic unit

4. Install new O-ring seals (11) and (12) on the

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

Electronic Unit Injector Sleeve

Contaminants may cause rapid wear and shortened

1. Drain the coolant from the engine. Refer to

8. Install harness assembly (1) and support bracket

9. Connect harness assembly (1) to electronic unit

10. Install bridge assemblies (3) in the respective

2. Install Tooling (A) in electronic unit injector sleeve

3. Tighten the nut on Tooling (A) until the electronic g01043165

4. Lubricate O-ring seals (2) with clean engine oil.

5. Position Tooling (A) and the electronic unit injector

a. Remove the exhaust elbow. Refer to Disassembly

Dispose of all fluids according to local regulations and

Contaminants may cause rapid wear and shortened

1. Disconnect the air hoses for the turbocharger inlet

2. Follow Steps 2.a through 2.c in order to remove

a. Remove tube clamp (9) that secures tube

b. Disconnect tube assembly (7) from the engine

c. Remove bolts (3). Remove tube assembly (7)

3. Follow Steps 3 through 3.c in order to remove the