Perkins 1506D Engine Manual

UENR4511-01 (en-us)
December 2015
Disassembly and Assembly

1506A-E88TA, 1506C-E88TA and
1506D-E88TA Industrial Engines
LG (Engine)
PK9 (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.
UENR4511-01 3
Table of Contents
Table of Contents Valve Mechanism Cover Base - Remove and

Install ...............................................................91
Rocker Arm and Shaft - Remove ..........................93
Disassembly and Assembly Section Rocker Arm - Disassemble...................................94
Rocker Arm - Assemble .......................................95
Fuel Priming Pump - Remove and Install ................5 Rocker Arm and Shaft - Install ..............................96
Fuel Filter Base - Remove .....................................6 Cylinder Head - Remove......................................98
Fuel Filter Base - Remove (Option 2) ......................7 Cylinder Head - Install ....................................... 102
Fuel Filter Base - Disassemble ...............................8 Lifter Group - Remove and Install ....................... 107
Fuel Filter Base - Disassemble (Option 2) ...............9 Camshaft - Remove .......................................... 108
Fuel Filter Base - Assemble .................................10 Camshaft - Install .............................................. 110
Fuel Filter Base - Assemble (Option 2).................. 11 Camshaft Gear - Remove and Install ................. 111
Fuel Filter Base - Install ...................................... 11 Camshaft Bearings - Remove ............................ 113
Fuel Filter Base - Install (Option 2)........................13 Camshaft Bearings - Install ................................ 113
Water Separator and Fuel Filter (Primary) - Remove Engine Oil Pan - Remove and Install .................. 115
and Install .........................................................14 Cylinder Liner - Remove .................................... 118
Electronic Unit Injector - Remove..........................17 Cylinder Liner - Install ........................................ 119
Electronic Unit Injector - Install .............................19 Piston Cooling Jets - Remove and Install ............ 120
Electronic Unit Injector Sleeve - Remove ..............21 Pistons and Connecting Rods - Remove ............. 121
Electronic Unit Injector Sleeve - Install ..................23 Pistons and Connecting Rods - Disassemble ...... 122
Unit Injector Hydraulic Pump - Remove.................24 Pistons and Connecting Rods - Assemble........... 123
Unit Injector Hydraulic Pump - Install ....................25 Pistons and Connecting Rods - Install................. 124
Air Cleaner - Remove and Install ..........................27 Connecting Rod Bearings - Remove ................... 125
Turbocharger - Remove.......................................29 Connecting Rod Bearings - Install....................... 126
Turbocharger - Install ..........................................30 Crankshaft Main Bearings - Remove (Crankshaft in
Exhaust Manifold - Remove and Install ................32 Position) ......................................................... 127
Exhaust Elbow - Remove and Install ....................35 Crankshaft Main Bearings - Install (Crankshaft in
Inlet and Exhaust Valve Springs - Remove and Position) ......................................................... 128
Install ...............................................................36 Crankshaft - Remove......................................... 130
Inlet and Exhaust Valves - Remove and Install.......38 Crankshaft - Install ............................................ 132
Inlet and Exhaust Valve Guides - Remove and Crankshaft Gear - Remove and Install ................ 137
Install ...............................................................40 Bearing Clearance - Check ................................ 138
Engine Oil Filter Base and Oil Cooler - Remove ....41 Refrigerant Compressor - Remove and Install .... 139
Engine Oil Filter Base and Oil Cooler - Install ........43 Atmospheric Pressure Sensor - Remove and
Engine Oil Pump - Remove ..................................46 Install ............................................................. 142
Engine Oil Pump - Disassemble ...........................47 Coolant Temperature Sensor - Remove and
Engine Oil Pump - Assemble................................49 Install ............................................................. 143
Engine Oil Pump - Install......................................51 Engine Oil Pressure Sensor - Remove and
Water Pump - Remove ........................................52 Install ............................................................. 144
Water Pump - Disassemble .................................53 Fuel Pressure Sensor - Remove and Install......... 145
Water Pump - Assemble .....................................54 Fuel Pressure Sensor - Remove and Install (Option
Water Pump - Install ............................................56 2) ................................................................... 146
Water Temperature Regulator - Remove and Fuel Temperature Sensor - Remove and Install ... 147
Install ...............................................................57 Injection Actuation Pressure Sensor - Remove and
Engine Lifting Bracket - Remove and Install ..........60 Install ............................................................. 148
Engine Support (Front) - Remove and Install .........62 Speed/Timing Sensor - Remove and Install ........ 150
Engine Support (Front) - Remove and Install (Option Inlet Manifold Temperature Sensor - Remove and
2) .....................................................................64 Install ............................................................. 151
Flywheel - Remove..............................................65 Inlet Manifold Pressure Sensor - Remove and
Flywheel - Install .................................................66 Install ............................................................. 152
Crankshaft Rear Seal - Remove ...........................68 V-Belts - Remove and Install (Charging Alternator
Crankshaft Rear Seal - Install...............................68 Drive Belts) ..................................................... 154
Flywheel Housing - Remove and Install ................69 V-Belts - Remove and Install (Water Pump Drive
Vibration Damper and Pulley - Remove and Install 72 Belt) ............................................................... 155
Crankshaft Front Seal - Remove ..........................74 Alternator Belt - Remove and Install ................... 156
Crankshaft Front Seal - Install ..............................75 Idler Pulley - Remove and Install (Grooved Idler
Front Cover - Remove .........................................75 Pulley) ............................................................ 157
Front Cover - Install .............................................76 Belt Tensioner - Remove and Install.................... 158
Gear Group (Front) - Remove ..............................77 Fan - Remove and Install .................................. 159
Gear Group (Front) - Install ..................................78 Fan Drive - Remove ......................................... 160
Housing (Front) - Remove....................................80 Fan Drive - Disassemble ................................... 161
Housing (Front) - Install .......................................81 Fan Drive - Assemble ....................................... 162
Crankcase Breather - Remove and Install ............83 Fan Drive - Install .............................................. 164
Cylinder Block Cover - Remove and Install............84 Electronic Control Module - Remove and Install... 164
Valve Mechanism Cover - Remove and Install .......88 Alternator - Remove and Install ......................... 167
4 UENR4511-01
Table of Contents
Alternator - Remove and Install (High Mounted

Alternator)....................................................... 169
Electric Starting Motor - Remove and Install ....... 172
Air Compressor - Remove and Install ................. 174
Index Section
Index................................................................ 177
UENR4511-01 5
Disassembly and Assembly Section
Disassembly and 3. Remove gasket (3).
Assembly Section Installation Procedure

NOTICE
i05986296 Keep all parts clean from contaminants.
Fuel Priming Pump - Remove Contaminants may cause rapid wear and shortened
component life.
and Install
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Turn the fuel supply to the OFF position. Illustration 2 g03778539

Typical example
1. Position a new gasket (3) on fuel filter base (4).
Note: Ensure correct orientation of the joint.
2. Position fuel priming pump (1) on fuel filter base

(4) and install bolts (2). Tighten the bolt to a torque
of 12 N·m (105 lb in). Tighten the bolt to a torque
of 28 N·m (248 lb in).
3. Turn the fuel supply to the ON position.
Illustration 1 g03778539
Typical example
2. Remove bolts (2). Remove fuel priming pump (1)

from fuel filter base (4).
6 UENR4511-01
4. Remove the air from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.
i05986293
Fuel Filter Base - Remove

Removal Procedure
NOTICE
and mandates.
NOTICE
component life.
Typical example
1. Turn the fuel supply to the “OFF” position.
2. Place a suitable container below the fuel filter base 3. Disconnect harness assembly (4) from fuel
in order to catch any fuel that might be spilled. pressure sensor (3) and fuel temperature sensor
(7).
4. Disconnect hose assembly (5) and hose assembly
(6). Remove O-ring seal (7) (not shown) and O-
ring seal (9) (not shown). Plug the open hose
assemblies and open port on the connections
secondary fuel filter base (10).
5. Use a suitable tool in order to remove secondary
fuel filter (11). Remove the O-ring seal. Refer to
Secondary Filter - Replace” for more information.
6. Remove bolts (1) and washers (2). Support the
fuel filter base (10) as the bolts are removed.
Remove fuel filter base (10).
UENR4511-01 7
NOTICE
component life.
1. Turn the fuel supply to the “OFF” position.

2. Place a suitable container below the fuel filter base
to catch any fuel that might be spilled.
Typical example
7. If necessary, follow Step 7.a through Step 7.b in

order to remove bracket (12) from the cylinder
block.
a. If necessary, remove the assembly of primary
fuel filter. Refer to Disassembly and Assembly,
“Water Separator and Fuel Filter (Primary) -
Remove and Install” for the correct procedure.
b. Remove bolts (14) and washers (13). Remove Typical example

bracket (12) from the cylinder block.
3. Cut cable strap (4). Disconnect fuel pressure
i06539447 sensor (5) from the engine harness.
4. Disconnect tube assembly (3) and hose assembly
Fuel Filter Base - Remove (6). Plug the open hose assemblies and open port
on the connections secondary fuel filter base (7).
(Option 2)
5. Use a suitable tool to remove secondary fuel filter
(8). Remove the O-ring seal. Refer to Operation
and Maintenance Manual, “Fuel System
Removal Procedure Secondary Filter - Replace” for more information.
NOTICE 6. Remove bolts (1) and washers (2). Support the
Care must be taken to ensure that fluids are con- fuel filter base (7) as the bolts are removed.
nance, testing, adjusting and repair of the product. Remove fuel filter base (7).
and mandates.
8 UENR4511-01
Typical example
7. If necessary, follow Step 7.a through Step 7.b to

remove bracket (12) from the cylinder block.
a. If necessary, remove the assembly of primary Illustration 7 g03779438

fuel filter. Refer to Disassembly and Assembly, Typical example
Remove and Install” for the correct procedure. 1. Remove fuel priming pump (17) from fuel filter
base assembly (22). Refer to Disassembly and
b. Remove bolts (9) and washers (13). Remove
Assembly, “Fuel Priming Pump - Remove and
bracket (11) and bracket (12) from the cylinder
Install” for the correct procedure.
block.
2. Remove fuel temperature sensor (6) from fuel filter
i05986291 base assembly (22). Refer to Disassembly and
Assembly, “Fuel Temperature Sensor - Remove
Fuel Filter Base - Disassemble and Install” for the correct procedure.
3. Remove fuel pressure sensor (4) from fuel filter
Disassembly Procedure Assembly, “Fuel Pressure Sensor - Remove and
Start By:
4. Remove adapter (3) from fuel filter base assembly
a. Remove the fuel filter base. Refer to (22). Remove the O-ring seal (5) from the adapter.
Disassembly and Assembly, “Fuel Filter Base -
Remove” for the correct procedure. 5. Remove fuel check valve (2) from fuel filter base
assembly (22). Remove the O-ring seal (1) from
NOTICE the fuel check valve.
6. Remove fuel check valve (16) from fuel filter base
Contaminants may cause rapid wear and shortened assembly (22). Remove the O-ring seal (15) from
component life.
the fuel check valve.
7. Make temporary marks on elbow connection (11)
for installation purposes. Loosen locking nut (10)
and remove elbow connection from adapter (8).
Remove O-ring seal (9) from the elbow
connection.
UENR4511-01 9

(22). Remove the O-ring seal (7) from the adaptor.
for installation purposes. Loosen locking nut (13)
and remove elbow connection from fuel filter base
assembly (22). Remove O-ring seal (14) from the
elbow connection.
10. Remove plug (19), and plug (20) from fuel filter
base assembly (22). Remove the O-ring seal (18)
and O-ring seal (21) from the plugs.
i06541703
Fuel Filter Base - Disassemble

(Option 2)
Disassembly Procedure
Start By:
a. Remove the fuel filter base. Refer to
Remove (Option 2)” for the correct procedure.
NOTICE Illustration 8 g06015010

Keep all parts clean from contaminants. Typical example
component life. 1. Remove fuel priming pump (1) from fuel filter base
assembly (15). Refer to Disassembly and
2. Remove fuel pressure sensor (10) from elbow
connection (11). Refer to Disassembly and
Assembly, “Fuel Pressure Sensor - Remove and
(15). Remove the O-ring seal (5) from the adapter.
4. Remove fuel check valve (13) from fuel filter base
assembly (15). Remove O-ring seal (14) and cap
(12) from the fuel check valve.
5. Make temporary marks on elbow connection (2) for
installation purposes. Loosen locking nut (3) and
remove elbow connection from fuel filter base
assembly (15). Remove O-ring seal (4) from the
elbow connection.
for installation purposes. Remove elbow
connection from fuel filter base assembly (15).
Remove O-ring seal (9) from the elbow
connection.
10 UENR4511-01
7. Remove plug (7) from fuel filter base assembly 3. Install a new O-ring seal (14) to elbow connection
(15). Remove the O-ring seal (8) from the plug. (12). Install the elbow connection into fuel filter
base assembly (22). Align the elbow connection
i05986289 with the temporary marks. Tighten locking nut (13)
to a torque of 50 N·m (37 lb ft). Ensure that the
Fuel Filter Base - Assemble elbow connection remains align after the locking
nut is tightened.
Assembly Procedure 4. Install a new O-ring seal (7) to adapter (8). Install
the adapter into fuel filter base assembly (22).
Tighten the adapter to a torque of 50 N·m (37 lb ft)
NOTICE .
5. Install a new O-ring seal (9) to elbow connection
Contaminants may cause rapid wear and shortened (11). Install the elbow connection to adapter (8).
component life. Align the elbow connection with the temporary
marks. Tighten locking nut (10) to a torque of
1. Ensure that the all components of the filter base 50 N·m (37 lb ft). Ensure that the elbow
are clean and free from damage. If necessary, connection remains align after the locking nut is
replace any component that is worn or damaged tightened.
6. Install a new O-ring seal (15) to fuel check valve
(16). Install the fuel check valve into fuel filter base
assembly (22). Tighten the fuel check valve to a
torque of 65 N·m (48 lb ft).
7. Install a new O-ring seal (1) to fuel check valve (2).
Install the fuel check valve into fuel filter base
assembly (22). Tighten the fuel check valve to a
8. Install a new O-ring seal (5) to adapter (8). Install
.
9. Install fuel pressure sensor (4) to adapter (8).
Refer to Disassembly and Assembly, “Fuel
Pressure Sensor - Remove and Install” for the
correct procedure.
10. Install fuel temperature sensor (6) to fuel filter
Assembly, “Fuel Temperature Sensor - Remove
and Install” for the correct procedure.
11. Install fuel priming pump (17) to fuel filter base
Typical example
2. Install a new O-ring seal (18), and a new O-ring

seal (21) to plug (19), and plug (20). Install the
plugs into fuel filter base assembly (22). Tighten
plugs to a torque of 40 N·m (30 lb ft).
UENR4511-01 11
End By: 3. Install a new O-ring seal (4) to elbow connection

(3). Install the elbow connection into fuel filter base
a. Install the fuel filter base. Refer to Disassembly assembly (15). Align the elbow connection with the
and Assembly, “Fuel Filter Base - Install” for
the correct procedure. temporary marks. Tighten locking nut (3) to a
torque of 50 N·m (37 lb ft). Ensure that the elbow
i06541719
connection remains aligned after the locking nut is
tightened.
Fuel Filter Base - Assemble 4. Install a new O-ring seal (9) to elbow connection
(11). Install the elbow connection to fuel filter base
(Option 2) assembly (15). Align the elbow connection with the
temporary marks. Tighten elbow connection (11)
to a torque of 40 N·m (30 lb ft).
Assembly Procedure 5. Install a new O-ring seal (14) to fuel check valve
(13). Install the fuel check valve into fuel filter base
NOTICE assembly (15). Tighten the fuel check valve to a
component life. 6. Install a new O-ring seal (5) to adapter (6). Install
1. Ensure that the all components of the filter base .
are clean and free from damage. If necessary,
replace any component that is worn or damaged 7. Install fuel pressure sensor (10) to elbow
connection (11). Refer to Disassembly and
Assembly, “Fuel Pressure Sensor - Remove and
8. Install fuel priming pump (1) to fuel filter base
End By:
a. Install the fuel filter base. Refer to Disassembly
and Assembly, “Fuel Filter Base - Install
(Option 2)” for the correct procedure.
i05986292
Fuel Filter Base - Install

Installation Procedure
NOTICE
component life.
Illustration 10 g06015010 1. Ensure that all components of the fuel filter base
Typical example are free from wear or damage. If necessary,
replace any component that is worn or damaged.
2. Install a new O-ring seal (8) to plug (7). Install the
plug into fuel filter base assembly (15). Tighten
plugs to a torque of 40 N·m (30 lb ft).
12 UENR4511-01
Typical example

order to install bracket (12) to the cylinder block.
a. Position bracket (12) onto the cylinder block. Illustration 12 g03778700

Install washers (3) to bolts (14). Torque bolts Typical example
to a torque of 240 N·m (177 lb ft).
3. Position fuel filter base (10) and install washers (2)
b. If necessary, install the assembly of primary
and bolts (1). Tighten the bolts to a torque of
55 N·m (41 lb ft).
Remove and Install” for the correct procedure. 4. Install a new O-ring seal to secondary fuel filter
(11). Install the secondary fuel filter. Refer to
5. Install a new O-ring seal (8) (not shown) and a new
O-ring seal (9) (not shown). Ensure that the O-ring
seals are correctly located into the recess of the
elbow connections
6. Connect hose assembly (5). Connect hose
assembly (6). Securely tighten the hose
assemblies to the elbow connections.
7. Connect harness assembly (4) to fuel pressure
sensor (3) and fuel temperature sensor (7).
8. Turn the fuel supply to the ON position.
UENR4511-01 13

i06541738
Fuel Filter Base - Install

(Option 2)
NOTICE
component life.
3. Position fuel filter base (7) and install washers (2)

and bolts (1). Tighten the bolts to a torque of
28 N·m (21 lb ft).
4. Install a new O-ring seal to secondary fuel filter (8).
Install the secondary fuel filter. Refer to Operation
and Maintenance Manual, “Fuel System
5. Connect hose assembly (6). Securely tighten the
hose assembly to the elbow connection.
6. Connect tube assembly (3). Securely tighten the
tube assembly to the adaptor.
7. Connect the engine harness to fuel pressure
sensor (5).
8. Secure fuel pressure sensor (5) to the bracket
using a new cable strap (4).
Typical example 9. Turn the fuel supply to the ON position.
1. Ensure that all components of the fuel filter base

are free from wear or damage. If necessary,
replace any component that is worn or damaged.
install bracket (12) to the cylinder block.
a. Position bracket (12) onto the cylinder block.

Install washers (10) to bolts (9). Install bracket
(11) to one bolt (9). Torque bolts to a torque of
55 N·m (41 lb ft).
b. If necessary, install the assembly of primary

14 UENR4511-01

i05986494
Water Separator and Fuel

Filter (Primary) - Remove and
Install
Removal Procedure
NOTICE
and mandates.
NOTICE
Keep all parts clean from contaminants. Illustration 15 g03780720
Contaminants may cause rapid wear and shortened Typical example

component life.
4. Disconnect hose assembly (3) from the assembly
of primary fuel filter (5).
1. Turn the battery disconnect switch to the OFF
position. 5. Remove bolts (1) and washers (2). Position
bracket (4) away from the assembly of primary fuel
2. Turn the fuel supply to the OFF position.
filter (5). Remove the assembly of primary fuel
3. Place a suitable container below the fuel filter base filter (5) from the mounting bracket.
in order to catch any fuel that might be spilled.
UENR4511-01 15
Typical example
7. If necessary, follow Step 7.a through Step 6.e in

block.
a. If necessary, remove the fuel filter base. Refer
Typical example
to Disassembly and Assembly, “Fuel Filter
Base - Remove” for the correct procedure.
order to disassembly the assembly of primary fuel b. Remove bolts (22) and washers (21). Remove
filter (5). bracket (20) from the cylinder block.
a. Remove adaptor (7) and remove O-ring seal Installation Procedure
(6).
NOTICE
b. Remove plug (7) and remove O-ring seal (9). Keep all parts clean from contaminants.
c. Remove plug (14). Contaminants may cause rapid wear and shortened
component life.
d. Remove plug (11), plug (12), plug (17), and
plug (18). Remove O-ring seal (10), O-ring
seal (13), O-ring seal (16), and O-ring seal 1. Ensure that the fuel filter base is clean and free
(19) from plugs. from damage. If necessary, replace the complete
fuel filter base and filter assembly.
e. Remove fuel filter canister (15). Refer to
Operation and Maintenance Manual, “Fuel
System Primary Filter (Water Separator)
Element - Replace” for the correct procedure.
16 UENR4511-01
Typical example
2. If necessary, follow Step 2 through Step 4 in order

to install bracket (20) from the cylinder block.
3. Position bracket (20) to the cylinder block. Install
washers (21) to bolts (22). Install bolts (22) to
bracket (20). Tighten bolts to a torque of 240 N·m Typical example
(177 lb ft)
4. If necessary, install the fuel filter base. Refer to order to assembly primary fuel filter (1).
Remove” for the correct procedure. a. Install a new filter element (15). Refer to
System Primary Filter (Water Separator)
Element - Replace” for the correct procedure.
b. Install a new O-ring seal (6) to adaptor (7).

Install adaptor (7) to the assembly of primary
fuel filter (5). Tighten the adaptor to a torque of
30 N·m (266 lb in).
c. Install a new O-ring seal (9) to plug (8). Install

plug (8) to the assembly of primary fuel filter
(5). Tighten the plug to a torque of 22 N·m
(195 lb in).
d. Install plug (14) to the assembly of primary

fuel filter (5). Tighten the plug to a torque of
30 N·m (266 lb in).
e. Install a new O-ring seal (10) O-ring seal (13),

O-ring seal (16), O-ring seal (19) to plug (11),
plug (12), plug (17), and plug (18). Install plug
(11), plug (12), plug (17), and plug (18) to
assembly primary fuel filter (5). Tighten the
plugs to a torque of 30 N·m (266 lb in).
UENR4511-01 17
End By:
a. Remove the air from the fuel system. Refer to
System - Prime” for the correct procedure.
i05986707
Electronic Unit Injector -

Remove
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
Fuel Injector Installer and

A T401081 2
Removal Tooling
Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
correct procedure.
Typical example NOTICE
6. Position the assembly of primary fuel filter (5) onto tained during performance of inspection, mainte-
the mounting bracket. Position bracket (4) to the Be prepared to collect the fluid with suitable contain-
assembly of primary fuel filter (5). ers before opening any compartment or disassem-
7. Install washers (2) to bolts (1). Install bolts (1) to bling any component containing fluids.
the assembly of primary fuel filter (5). Tighten the Dispose of all fluids according to local regulations
bolts to a torque of 55 N·m (41 lb ft). and mandates.
8. Connect hose assembly (3) to the assembly of
primary fuel filter (5). NOTICE
9. Turn the fuel supply to the ON position. Keep all parts clean from contaminants.
10. Turn the battery disconnect switch to the ON Contaminants may cause rapid wear and shortened
position. component life.
18 UENR4511-01
Illustration 21 g03775306 Illustration 22 g03774344
1. Remove plug (1) from the rear of the cylinder

head. Remove O-ring seal (2) (not shown) from
the plug. Allow the engine oil to drain from the
cylinder head before the unit injector is removed.
2. Use a suitable tool to disconnect harness

assembly (3) from electronic unit injector (4).
3. Remove Allen head bolts (5) from electronic unit
injector (4).
4. Install Tooling (A) to electronic unit injector (4).
5. Use Tooling (A) to remove electronic unit injector
(4) from the cylinder head.
Note: Do not use a wire brush on the tip of the

electronic unit injector. Damage to the unit injector
will occur.
UENR4511-01 19
(Table 2, contd)
F T401080 Seal Installer 1
GE50028 Vacuum Pump 1
GE50046 Bottle Assembly 1

G
Clear Plastic Tubing
GE50030 1
7.92 mm (0.312 inch) OD
H T401077 Reamer 1
J T401078 Tube Brush 1
K GE50023 Tapered Brush 1
L - Vacuum Gun Kit 1
M - Tap Wrench 1
NOTICE
component life.
1. Evacuate as much fuel and oil as possible from the

cylinder head before installing the electronic unit
injector. Several evacuations may be necessary.
Use Tooling (G) to remove the fuel and oil from the
Illustration 24 g03774348 cylinder head.
Note: Tooling (L) is available to clean loose material
6. Remove O-ring seal (8) from electronic unit from the sleeve bore for electronic unit injector and
injector (4). the cylinder.
7. Remove O-ring seal (9) and backup ring (10) from
2. Inspect the electronic unit injector sleeve for
electronic unit injector (2).
damage and carbon deposits.
8. Remove O-ring seal (7) and backup ring (6) from
3. Clean the carbon from the sleeve for the electronic
unit injector (4).
unit injector, the sleeve bore. Clean the carbon
9. If necessary, follow Step 2 through Step 8 in order from the end of the electronic unit injector, if the
to remove the remaining electronic unit injector electronic unit injector is being reused. Clean the
(4). carbon from the seat area that is inside of the
cylinder head. A fine grade of Scotch Brite
i05986518 material is preferred. Use Tooling (H) to clean the
bore of the electronic unit injector tip. Use the
Electronic Unit Injector - Install Surface Reconditioning Pad in order to clean the
carbon in the cylinder head. Use Tooling (J) in
order to remove the carbon from the surface of the
sleeve.
Table 2 Note: Using power tools in order to rotate the
material should not be necessary. The carbon in the
Required Tools
electronic unit injector sleeve is more removable than
Tool Part Number Part Description Qty the carbon at locations that are exposed to higher
temperatures.
Fuel Injector Installer and Re-
A T401081 2
moval Tooling The following procedure is the preferred method of
cleaning the sleeve bore.
E T401079 Seal Protector 1
(continued)
20 UENR4511-01
Place a 38 mm (1.5 inch) square piece of Scotch

Brite material on the end of Tooling (K). Twist
Tooling (K) with Tooling (M) against the lower
surface of the electronic unit injector sleeve bore.
The surface should be cleaned until the surface is
smooth and shiny. The entire sleeve bore should
be cleaned in order to remove any loose carbon
particles.
Note: Tooling (J) is available to clean loose material
from the electronic unit injector sleeve bore and the
cylinder.
4. When you install a new electronic unit injector, the

E-Trim value must be programmed into the
Electronic Control Module (ECM). The E-Trim
value is a six digit alphanumeric code that is
supplied with the data sheet that comes with the
new electronic unit injector. Use the following
menu to program the E-Trim value.
• ECM Summary Screen
• Service Menu
• Calibration
• Electronic Unit Injector Code Calibration

NOTICE
The correct procedures and tooling specifications 5. The correct installation of the electronic unit
must always be used. Failure to follow any of the pro- injector is important. Damage to the upper high-
cedures may result in damage, malfunction, or possi- pressure seals can cause excessive oil leakage
ble engine failure. under the valve cover. The incorrect installation of
the electronic unit injector may cause the engine
not to start due to a low actuation pressure.
NOTICE
The O-ring seals and the backup rings must be in- Damage to the lower high-pressure seals may
stalled in the correct orientation. Damaged seals will allow high-pressure oil to leak into the fuel supply
result in excessive oil consumption or excessive leak- passage. Damage to the lower high-pressure
age under the valve cover. Use care to prevent nicks seals will result in excessive oil consumption.
or damage to the seals.
6. Use Tooling (E) and Tooling (F) to install backup
ring (6) to electronic unit injector (4).
Note: Do not hit or strike the electronic unit
injector during installation. Do not use a wire 7. Lubricate a new O-ring seal (7) with clean engine
brush to clean the tip of the electronic unit oil. Install the O-ring seal to electronic unit injector
injector. Damage to the electronic unit injector (4).
will occur.
8. Use Tooling (E) and Tooling (F) to install backup
ring (10) to unit injector (4).
9. Lubricate a new O-ring seal (9) with clean engine
oil. Install the O-ring seal to electronic unit injector
(4).
10. Lubricate a new O-ring seal (8) with clean engine
oil. Install the O-ring seal to electronic unit injector
(4).
UENR4511-01 21
16. Install a new O-ring seal (2) (not shown) to plug

(1). Install the plug (1) to the rear of the cylinder
head. Tighten the plug to a torque of 400 N·m
(295 lb ft).
End By:
a. Install the valve mechanism cover. Refer to
correct procedure.
i05986716
Electronic Unit Injector Sleeve

Illustration 27 g03774344 - Remove
11. Lubricate the bore of the sleeve for electronic unit
injector (4) with clean engine oil.
Removal Procedure
12. Position electronic unit injector (4) into sleeve for
Table 3
the electronic unit injector. Ensure that the
electronic unit injector is correctly orientated. Required Tools

13. Use Tooling (A) to install electronic unit injector
(4) in the cylinder head. A T401082 Plug Tap 1
14. Install Allen head bolt (5) on the exhaust side of B T401083 Guide Sleeve 1
the bracket. Tighten the exhaust side of Allen head Bridge Plate
T401084 1
bolt (5) until the bolt is seated. Tighten the inlet
side of Allen head bolt (5) to a torque of 12 N·m T401085 Puller Stud 1
(106 lb in). C T401086 Full Nut 1
15. Connect harness assembly (3) to electronic unit T401087 Hard Washer 1
injector (4). T401088 Thrust Bearing 1
D T401064 Rubber Stopper 1
22 UENR4511-01
Start By:
a. Remove the unit injectors. Refer to
Disassembly and Assembly, “Unit Injector -
Remove” for the correct procedure.
NOTICE
component life.
NOTICE
and mandates.
1. Drain the coolant from the cooling system into a

suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant (ELC) - Change” for the correct
procedure.
2. Position Tooling (D) at the bottom of electronic unit

injector sleeve (1).
3. Coat Tooling (A) with clean grease. Use Tooling
(A) and Tooling (B) to cut threads into electronic
unit injector sleeve (1).
4. Install Tooling (C) in electronic unit injector sleeve
(1).
5. Remove electronic unit injector sleeve (1) (not
shown). Remove O-ring seals (2).
UENR4511-01 23

to remove the remaining electronic unit injector
sleeve.
i05986722
Electronic Unit Injector Sleeve

- Install
Table 4
Required Tools
E T401065 Sleeve Installer 1
F T401066 Large Bore Brush 1
G T401067 Retaining Compound 1

NOTICE
component life.
1. Thoroughly clean a new electronic unit injector

sleeve (1) and the bores for the unit injectors with
Tooling (F).
2. Apply clean engine oil to O-ring seals (2). Install
the O-ring seals on electronic unit injector sleeve
(1).
3. Position electronic unit injector sleeve (1) on
Tooling (E).
4. Apply a thin coating of Tooling (G) around the outer
circumference of electronic unit injector sleeve (1)
at Area (C).
24 UENR4511-01
5. Position electronic unit injector sleeve (1) in the

cylinder head. Use a hammer to install the
electronic unit injector sleeve into the cylinder
head.
Note: Allow Tooling (G) to cure for two hours at 21 °C
(70 °F) before filling the engine with fuel or coolant.
Longer curing time is required for lower
temperatures.

to install remaining the electronic unit injector
sleeve.
7. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
Manual, “Cooling System Coolant (ELC) -
Change” for the correct procedure.
End By:
a. Install the unit injectors. Refer to Disassembly
and Assembly, “Unit Injector - Install” for the Illustration 33 g03782498
correct procedure.
1. Disconnect harness assembly (1) from unit injector
i05986486
hydraulic pump (2).
Unit Injector Hydraulic Pump - 2. Remove hose assembly (6) and hose assembly (7)
from fuel transfer pump (5).
Remove
3. Remove hose assembly (4) and breather (3).
Refer to Disassembly and Assembly, “Crankcase
Breather - Remove and Install” for the correct
Removal Procedure procedure.
NOTICE
component life.
NOTICE
and mandates.
4. Remove tube assembly (8) from unit injector

hydraulic pump (2) and elbow connection (15).
UENR4511-01 25
5. Remove tube assembly (13) from fuel transfer pump (5).

pump (5) and the cylinder head.
g. Remove O-ring seal (22) (not shown).
6. Remove O-ring seal (12) (not shown) and O-ring
seal (14) (not shown) from the connections. h. Remove connection (26) and connection (31)
from fuel transfer pump (5).
7. Remove bolts (9) from unit injector hydraulic pump
(2). Support the unit injector hydraulic pump as the i. Remove O-ring seal (25) and O-ring seal (30).
bolts are removed.
11. If necessary, follow Step 11.a through Step 11.b
8. Remove unit injector hydraulic pump (2) from to remove fuel transfer pump (5).
housing front (10).
a. Remove Torx bolts (28) and Torx bolts (29).
9. Remove O-ring seal (11) (not shown).
Remove fuel transfer pump (5) from unit
injector hydraulic pump (2).
b. Remove O-ring seal (27) (not shown).
i05986485
Unit Injector Hydraulic Pump -

Install
Removal Procedure
NOTICE
component life.
NOTICE
Illustration 35 g03782516 Care must be taken to ensure that fluids are con-
10. If necessary, follow Step 10.a through Step 10.i in
order to disassemble unit injector hydraulic pump ers before opening any compartment or disassem-
(2). bling any component containing fluids.
a. Use a suitable tool in order to prevent unit Dispose of all fluids according to local regulations
injector hydraulic pump gear (21) from and mandates.
rotating. Ensure that the gear is not damaged
as nut (19) is loosened. 1. Ensure that all the components of the unit injector
hydraulic pump are free from wear or damage.
b. Remove nut (19) and washer (20).
Replace any component that is worn or damaged.
c. Use a suitable tool to remove unit injector
hydraulic pump gear (21).
d. Make a temporary mark on connection (18) for

installation purposes. Loosen locking nut (17)
and remove the connection from unit injector
hydraulic pump (2).
e. Remove O-ring seal (16) (not shown).
f. Make a temporary mark on connection (24) for

installation purposes. Loosen locking nut (23)
and remove the connection from fuel transfer
26 UENR4511-01
e. Install a new O-ring seal (25) and a new O-ring

seal (30) to connection (26) and connection
(31).
f. Install connection (26) and connection (31) to

fuel transfer pump (5). Tighten the
connections, refer to Specifications, “Unit
Injector Hydraulic Pump” for the correct
tighten procedure.
g. Install a new O-ring seal (22) (not shown) to

connection (24). Install the connection to fuel
transfer pump (5) and align with temporary
marks.
h. Tighten locking nut (23), refer to
Specifications, “Unit Injector Hydraulic Pump”
for the correct tighten procedure. Ensure that
the connections are still align after the locking
nut has been tightened.
2. If necessary, follow Step 2.a through Step 2.d to

install fuel transfer pump (5).
a. Install a new O-ring seal (27) (not shown).
b. Install fuel transfer pump (5) to unit injector

hydraulic pump (2).
c. Install Torx bolts (28) and Torx bolts (29) hand

tight.
d. Tighten Torx bolts (28) and Torx bolts (29).

Refer to Specifications, “Unit Injector
Hydraulic Pump” for the correct tighten
procedure.
3. If necessary, follow Step 3.a through Step 3.h in
order to assemble unit injector hydraulic pump (2).
a. Ensure that the shaft of unit injector hydraulic Illustration 37 g03782499

pump (2) and unit injector hydraulic pump gear
(21) are clean and free from damage. 4. Install a new -ring seal (11) (not shown) to unit
injector hydraulic pump (2). Ensure that the O-ring
b. Install unit injector hydraulic pump gear (21),
seal is correctly seated into the recess of the unit
washer (20), and nut (19). Hand tighten the
injector hydraulic pump.
nut.
5. Install unit injector hydraulic pump (2) onto housing
c. Use a suitable tool in order to prevent unit
front (10).
injector hydraulic pump gear (21) from
rotating. Ensure that the gear is not damaged 6. Install bolts (9) to unit injector hydraulic pump (2).
as nut (19) is tightened. Support the unit injector hydraulic pump as the
bolts are installed.
d. Tighten nut (19), refer to Specifications, “Unit
Injector Hydraulic Pump” for the correct 7. Tighten bolts (9) to a torque of 55 N·m (41 lb ft).
tighten procedure.
UENR4511-01 27
8. Install a new O-ring seal (12) (not shown) and a 13. Install breather (3) and hose assembly (4). Refer
new O-ring seal (14) (not shown) to fuel transfer to Disassembly and Assembly, “Crankcase
pump (5) and the cylinder head. Ensure that the Breather - Remove and Install” for the correct
O-ring seals are correctly seated into the recess of procedure.
the connections.
i05986223
9. Install tube assembly (13) to fuel transfer pump (5)
and the cylinder head. Tighten the tube nuts for Air Cleaner - Remove and
the tube assembly to a torque of 65 N·m (48 lb ft).
10. Install tube assembly (8) to unit injector hydraulic Install
pump (2) and elbow connection (15). Tighten the
tube nuts for the tube assembly to a torque of
100 N·m (74 lb ft). Removal Procedure
NOTICE
component life.
11. Install hose assembly (6) and hose assembly (7)

to fuel transfer pump (5). Tighten the tube nuts for
the hose assemblies to a torque of 30 N·m
(266 lb in). Ensure that the hose assemblies are
not strained as the tube nuts are tightened. Illustration 39 g03749679
12. Connect harness assembly (1) to unit injector Typical example
hydraulic pump (2).
1. Loosen hose clamp (8) and hose clamp (10).
2. Remove hose assembly (9) from air cleaner
assembly (1) and the turbocharger.
3. Attach a suitable lifting device in order to support
the weight of air cleaner assembly (1). The weight
of the air cleaner is approximately 23 kg (51 lb).
4. Make temporary marks on clamp (2) for installation
purposes. Remove the nuts and bolts (3) from the
clamp. Remove the clamp from the air cleaner
assembly (1).
5. Use the suitable lifting device in order to remove
air cleaner assembly (1) from bracket (7).
28 UENR4511-01
6. If necessary, remove service indicator (6) from air

cleaner assembly (1).
7. If necessary, loosen hose clamp (5) and remove
rain cap (4) from air cleaner assembly (1).
Typical example
2. If necessary, follow Step 2.a through Step 2.d in

order to install bracket (7) onto the cylinder head.
Typical example a. Attach a suitable lifting device in order to
support the weight of bracket (7). The weight
8. If necessary, follow Step 2.b through Step 2.d in of the bracket is approximately 23 kg (51 lb).
b. Use the suitable lifting device in order to
head.
position bracket (7) onto the cylinder head.
a. Attach a suitable lifting device in order to
support the weight of bracket (7). The weight c. Install bolts (11) and bolts (12) to bracket (7)
of the bracket is approximately 23 kg (51 lb). hand tight.
b. Remove bolts (11) and bolts (12) from bracket d. Tighten bolts (11) to a torque of 55 N·m
(7). (41 lb ft).
Tighten bolts (12) to a torque of 100 N·m
c. Use the suitable lifting device in order to (74 lb ft).
remove bracket (7) from the cylinder head.
NOTICE
component life.
1. Ensure that the air cleaner assembly and the

bracket are free from wear or damage. Replace
any component that is worn or damaged.
UENR4511-01 29
10. Tighten the nuts and bolts (3) to a torque of

44 N·m (32 lb ft).
i06541855
Turbocharger - Remove
Removal Procedure
NOTICE
component life.
NOTICE
Illustration 42 g03749679 Be prepared to collect the fluid with suitable contain-
Typical example ers before opening any compartment or disassem-
3. If necessary, install service indicator (6) to air
cleaner assembly (1). Hand tighten the service and mandates.
indicator.
4. If necessary, install rain cap (4) onto air cleaner
assembly (1). Tighten hose clamp (5) to a torque
of 7 N·m (62 lb in).
5. Attach a suitable lifting device to air cleaner
assembly (1). The weight of the air cleaner is
approximately 23 kg (51 lb).
6. Use the suitable lifting device in order to position
air cleaner assembly (1) onto bracket (7).
7. Install clamp (2) onto air cleaner assembly (1).
Align the clamp to the original marks. Install bolts
(3) to the clamp and install new nuts. Hand tighten
the nuts and bolts.
8. Install hose assembly (9) onto air cleaner
assembly (1) and the turbocharger. Ensure that air
cleaner assembly (1) is correctly aligned in the
vertical position.
9. Tighten hose clamp (10) to a torque of 11 N·m
(97 lb in).
Tighten hose clamp (8) to a torque of 7 N·m Typical example.
(62 lb in).
Some engines may have a different configuration.
Some engines are equipped with a wastegate
actuator.
1. Remove exhaust elbow (3). Refer to Disassembly

and Assembly, “Exhaust Elbow - Remove and
30 UENR4511-01
2. Loosen hose clamp (4) and hose clamp (6).

Remove hose assembly (5).
3. Loosen hose clamps (2) and remove tube
assembly (1).
Typical example.
actuator.
8. Remove nuts (18) from turbocharger (9).

9. Attach a suitable lifting device onto turbocharger
(9). The weight of the turbocharger is
Illustration 44 g03781906 10. Remove turbocharger (9) from exhaust manifold
Typical example. (20).
11. Remove gasket (19) (not shown) from exhaust
Some engines are equipped with a wastegate manifold (20).
actuator.
12. If necessary, remove studs (17).
4. Disconnect hose assembly (7) from turbocharger
13. If necessary, remove adapter (16) from
(9). Position the hose assembly away from the
turbocharger (9). Remove O-ring seal (15) (not
turbocharger.
shown).
i06541865
6. Remove bolts (11) and bolts (14) from tube
assembly (12). Remove the tube assembly from Turbocharger - Install
turbocharger (9) and the cylinder block.
seal (13) (not shown).
Table 5
Required Tools
A CV6-0889 Anti-Seize Compound -
UENR4511-01 31
4. Attach a suitable lifting device to turbocharger (9).

NOTICE
Keep all parts clean from contaminants. The weight of the turbocharger is approximately
27 kg (60 lb).
component life. 5. Position a new gasket (19) (not shown) onto
exhaust manifold (20).
1. Ensure that all components of the turbocharger are 6. Apply Tooling (A) to studs (17).
free from wear or damage. If necessary, replace 7. Use the suitable lifting device to install
turbocharger as an assembly. Refer to turbocharger (9) to exhaust manifold (20).
Specifications, “Turbocharger” for further
information. 8. Install new nuts (18). Tighten the nuts to a torque
of 54 N·m (40 lb ft).
Typical example.
actuator.

install new studs (17).
Typical example.
a. Apply Tooling (A) to studs (17). Some engines may have a different configuration.
b. Install studs (17) to exhaust manifold (20). Some engines are equipped with a wastegate
actuator.
Tighten the studs to a torque of 25 N·m
(221 lb in). 9. Install new O-ring seal (10) (not shown) and new
3. If necessary, follow Step 3.a through Step 3.b to O-ring seal (13) (not shown) onto tube assembly
install adapter (16). (12).
a. Install a new O-ring seal (15) (not shown) to 10. Position tube assembly (12) onto turbocharger (9)
adapter (16). and the cylinder block. Ensure that the tube
assembly is correctly installed onto the
b. Install adapter (16) to turbocharger (9). turbocharger and the cylinder block. Install bolts
Tighten the adapter to a torque of 30 N·m (11) and bolts (14) to the tube assembly.
(266 lb in). 11. Tighten bolts (11) and bolts (14) to a torque of
28 N·m (248 lb in).
32 UENR4511-01
12. Lubricate the turbocharger bearings with clean 19. Tighten hose clamp (4) to a torque of 11 N·m
engine oil through the oil inlet port. Rotate the (97 lb in).
wheel of the compressor several times to lubricate
the bearings. i05986470
13. Install a new O-ring seal (8) (not shown) onto the
adapter. Ensure that the O-ring seal is correctly
Exhaust Manifold - Remove
installed into the recess of the adapter. and Install
14. Connect hose assembly (7) to turbocharger (9).
Tighten the tube nut for the adapter to a torque of
30 N·m (266 lb in). Removal Procedure
Start By:
a. Remove the turbocharger. Refer to
Disassembly and Assembly, “Turbocharger -
NOTICE
component life.
Typical example.
actuator.
15. Install exhaust elbow (3). Refer to Disassembly Exhaust manifold tightening sequence
and Assembly, “Exhaust Elbow - Remove and
16. Install tube assembly (1) and tighten hose clamps
(2) to a torque of 7 N·m (62 lb in).
17. Install hose assembly (5). Ensure that hose
assembly is correctly located onto the
turbocharger and the air filter assembly.
18. Install hose clamp (4) and hose clamp (6).
Tighten hose clamp (6) to a torque of 7 N·m
(62 lb in).
UENR4511-01 33
c. Remove the front section of exhaust manifold

(9) from the center section of exhaust manifold
(8).
d. If necessary, remove studs (7) from the center

section of exhaust manifold (9).
Table 6
Required Tools
A CV60889 Anti-Seize Compound 1
NOTICE
component life.
1. Ensure that all components of the exhaust
manifolds are free from wear or damage. Replace
1. Loosen nuts (2) and nuts (3) for the exhaust
any component that is worn or damaged.
manifold in the reverse sequence shown in
Illustration 55 .
2. Remove nuts (1), nuts (3), and spacers (2).
3. Remove exhaust manifold assembly (4) from the
cylinder head.
4. Remove gaskets (5) (not shown).
2. If necessary, follow Step 2.a through Step 2.f in

order to assemble the assembly of exhaust
manifold (4).
a. Place the assembly of exhaust manifold (4) in

Illustration 51 g03780724 a suitable support.
b. If necessary, install studs (7) to the center

5. If necessary, follow Step 2.a through Step 3 in
section of exhaust manifold (9). Tighten the
order to disassemble the assembly of exhaust
studs to a torque of 27 N·m (239 lb in).
manifold (4).
c. Apply Tooling (A) to Position (W) on rear
a. Place the assembly of exhaust manifold (4) in
section of exhaust manifold (6) and center
a suitable support.
b. Remove the rear section of exhaust manifold
(6) from the center section of exhaust manifold d. Install the rear section of exhaust manifold (6)
to the center section of exhaust manifold (8).
(8).
34 UENR4511-01
e. Apply Tooling (A) to Position (W) on front

section of exhaust manifold (9) and center
f. Install the front section of exhaust manifold (9)

to the center section of exhaust manifold (8).
Exhaust manifold tightening sequence
UENR4511-01 35
3. Check the condition of studs (10). If necessary

replace the studs. Tighten the studs to a torque of
27 N·m (239 lb in).
4. Position new gaskets (5) (not shown) on the
cylinder. Ensure that the gaskets are correctly
orientated.
5. Install exhaust manifold assembly (4) to the
cylinder head.
6. Install spacers (2) onto studs (10). The spacers are
only installed onto the top studs.
7. Install new nuts (1) and new nuts (3) to studs (10).
8. Tighten nuts (2) and nuts (3) to a torque of 55 N·m
(41 lb ft) in the sequence shown in Illustration 55 .
End By:
a. Install the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Install” for the
correct procedure. Illustration 56 g03780322
i05986263
1. Remove the Original Equipment Manufacture
(OEM) exhaust system (1) from exhaust elbow (7).
Exhaust Elbow - Remove and Refer to OEM for the correct procedure
Install 2. Remove the nuts and bolts (2) from bracket (3).
Remove the bracket from exhaust elbow (7).
3. Loosen V-band clamp (6) and remove exhaust
Removal Procedure elbow (7) and the V-band clamp. Support the
exhaust elbow as the V-band clamp is loosened.
NOTICE
Keep all parts clean from contaminants. 4. Remove exhaust elbow (7) and V-band clamp (6)
from turbocharger (5).
component life. 5. If necessary, follow Step 2.a through Step 3 in
order to remove bracket (4).
a. Remove bolts (8) (not shown) from bracket

(4).
b. Remove bracket (4) from the exhaust

manifold.
Installation Procedures
NOTICE
component life.
1. Ensure that the exhaust elbow and the bracket are

free from wear or damage. Replace any
components that are worn or damaged.
36 UENR4511-01
7. Install the OEM exhaust system (1) to exhaust

elbow (7). Refer to OEM for the correct procedure
i05986432
Inlet and Exhaust Valve

Springs - Remove and Install
Removal Procedure
Table 7
Required Tools
A T401068 Valve Spring Compressor 1
B CH11148 Turning Tool 1
Start By:
a. Remove the electronic unit injector. Refer to
2. If necessary, follow Step 2.a through Step 2.b in Disassembly and Assembly, “Electronic Unit
order to install bracket (4). Injector - Remove” for the correct procedure.
a. Position bracket (4) onto the exhaust manifold. NOTICE

b. Install bolts (8) (not shown) to bracket (4).
Tighten the bolts to a torque of 55 N·m Contaminants may cause rapid wear and shortened
component life.
(41 lb ft).
3. Install exhaust elbow (7) and V-band clamp (6) to
turbocharger (5). Hand tighten the V-band clamp. Note: The following procedure is for the removal of
the inlet valve springs and the exhaust valve springs
Support the exhaust elbow as the V-band clamp is
without removing the cylinder head. This procedure
tightened. can be performed on only one cylinder at a time.
4. Install bracket (3) onto exhaust elbow (7). Install Performing the procedure on only one cylinder at a
the nuts and bolts (2) to the bracket hand tight. time will prevent the inlet valves and the exhaust
valves from falling into the cylinder.
5. Tighten V-band clamp (6) to a torque of 13.5 N·m
(10 lb ft). 1. Use Tooling (B) to rotate the crankshaft in order to
bring the piston to the top center position in the
6. Tighten the nuts and bolts (2) to a torque of 55 N·m cylinder.
(41 lb ft).
UENR4511-01 37
Table 8
Required Tools
NOTICE
component life.
1. Install the valve spring seats for the inlet valve

springs and the exhaust valve springs.
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
2. Use Tooling (A) in order to compress the inlet valve

3. Remove valve keepers (4).
4. Remove Tooling (A).
5. Remove spring retainer (5).
6. Remove inner valve spring (6) and outer valve
spring (7) from each valve (1). Remove valve
spring seats (3) (not shown) from the cylinder Improper assembly of parts that are spring
loaded can cause bodily injury.
head.
To prevent possible injury, follow the established
7. If necessary, remove valve stem seals (2) (not
assembly procedure and wear protective
shown) from the valve guides. equipment.
8. Install the inlet valve springs and the exhaust
valve springs before you rotate the crankshaft. 2. If necessary, Install new valve stem seals (2) (not
shown) to the valve guides.
38 UENR4511-01
3. Install valve spring seats (3) (not shown) to the

cylinder head.
4. Install inner valve spring (4) and outer valve spring
(5) on each valve (1).
5. Install spring retainer (3). Install inner valve spring
(6) and outer valve spring (7) to each valve (1).
6. Use Tooling (A) in order to compress the inlet valve
7. Install valve keepers (4).
8. Remove Tooling (A).
End By:
a. Install the electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove” for the correct procedure.
i05986444
Inlet and Exhaust Valves -

Remove and Install
Removal Procedure
Table 9
Required Tools

Start By:
1. Place a temporary identification mark on the heads
a. Remove the cylinder head. Refer to of valves (7) in order to identify the correct
Disassembly and Assembly, “Cylinder Head - position.
NOTICE
Contaminants may cause rapid wear and shortened parts propelled by a released spring force.
component life.
equipment.
Follow the recommended procedure and use all
The valve spring keepers can be thrown from the
valve when the valve spring compressor is re- 2. Use Tooling (A) to compress valve springs (3) and
leased. Ensure that the valve spring keepers are
valve springs (4). Remove valve keepers (1).
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of Note: Do not compress the springs so that valve
the valve spring keepers and valve springs dur-
spring retainers (2) touches valve stem seals (5).
ing the installation of the valves.
3. Remove Tooling (A). Remove spring retainers (2)
and valve springs (3) and valve springs (4).
UENR4511-01 39
4. Remove valve stem seals (5), spring seat washer

(6).
5. Remove valves (7) from the cylinder head.
6. Repeat Step 1 through Step 5 in order to remove
remaining valves (7) from the cylinder head.
Table 10
Required Tools
NOTICE
component life.
1. Ensure all the components are free from wear or

damage. If necessary, replace any component that
is worn or damaged.
Improper assembly of parts that are spring

loaded can cause bodily injury.
assembly procedure and wear protective
equipment.
2. Install spring seat washer (6) and install new valve

stem seals (5) to the valve guides.
3. Lubricate the stems of valves (7) with clean engine
oil. Install the valve into the cylinder head.
4. Install valve springs (3) and valve springs (4).
Install spring retainers (2).
40 UENR4511-01
The valve spring keepers can be thrown from the

valve when the valve spring compressor is re-
leased. Ensure that the valve spring keepers are
properly installed on the valve stem. To help pre-
vent personal injury, keep away from the front of
the valve spring keepers and valve springs dur-
ing the installation of the valves.
5. Use Tooling (A) to compress valve springs (3) and

valve springs (4).
Note: Do not compress the springs so that valve

spring retainers (2) touches valve stem seals (5).
6. Install valve keepers (1) to spring retainers (2).

7. Repeat Step 2 through Step 6 in order to install
remaining valves (7) to the cylinder head.
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i05986472
Inlet and Exhaust Valve Guides Illustration 62 g03781704
- Remove and Install

1. Use Tooling (A) to remove inlet valve guides(1)
and exhaust valve guides (2) from the cylinder
head assembly.
Removal Procedure
Table 11
Table 12
Required Tools
Required Tools
GE50043
A or Valve Guide Driver 1 GE50043
27610262(1) A or ' Valve Guide Driver 1
27610262(1)
(1) If necessary, use Tooling on inlet valve guides.
B T401070 Guide Collar 1
Start By: C T401069 Guide Collar 1
(1) If necessary, use Tooling on inlet valve guides.
a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and
Exhaust Valves - Remove and Install” for the
correct procedure. NOTICE
NOTICE Contaminants may cause rapid wear and shortened
Keep all parts clean from contaminants. component life.
component life.
UENR4511-01 41
End By:
a. Install the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and
Exhaust Valves - Remove and Install” for the
correct procedure.
i05986996
Engine Oil Filter Base and Oil

Cooler - Remove
Removal Procedure
Table 13
Required Tools
A - Strap Wrench Assembly 1

NOTICE
component life.
NOTICE
and mandates.

System Coolant - Change” for the correct
procedure.
Valve guide protrusion
1. Position inlet valve guide (1) and exhaust valve

guide (1) in the cylinder head. Tap on the top of the
valve guides in order to start the inlet valve guides
and exhaust valve guides into the cylinder head
assembly.
2. Use Tooling (A) and Tooling (B) to install exhaust
valve guide (2). Use Tooling (A) and Tooling (C) to
install intake valve guide (1). Install the valve
guides until the protrusion is Distance (X).
Distance (X) is 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
above the cylinder head assembly.
42 UENR4511-01
2. Use Tooling (A) to remove engine oil filter (5) from

engine oil filter base (4).
3. Disconnect hose assembly (1) from elbow
connection (3). Remove O-ring seal (2) (not
shown).
4. Remove bolts (5) from engine oil filter base (4).
Support the engine oil filter base as the bolts are
removed.
5. Remove bolts (7). Remove engine oil filter base
(4). Remove gasket (6) (not shown).
6. Remove oil cooler core (9) from the cylinder block.
7. Remove gasket (8).
UENR4511-01 43

equipment.
Follow the recommended procedure and use
all recommended tooling to release the spring
force.
g. Remove plug (15) from engine oil filter base

(4). Remove O-ring seal (16).
h. Remove spring (19) and valve (22) from

i. Remove plug (28) from engine oil filter base

(4). Remove O-ring seal (27).
j. Remove spring (26) and valve (25) from

i05986414
Engine Oil Filter Base and Oil

Cooler - Install
8. If necessary, follow Step 8.a through Step 8.j in

order to disassemble engine oil filter base (4). Installation Procedure
Table 14
a. Make temporary marks on elbow connection
(10) and engine oil filter base (4) for Required Tools
installation purposes. Tool Part Number Part Description Qty
b. Remove cap (13) from valve (12). Remove the Guide Studs
A - 2
valve from elbow connection (10). Remove O- M8 by 60 mm
ring seal (11).
c. Loosen locking nut (17) and remove elbow NOTICE

connection (10). Remove O-ring seal (18). Keep all parts clean from contaminants.
d. Remove adapter (20) from engine oil filter Contaminants may cause rapid wear and shortened
component life.
base (4). Remove O-ring seal (24).
e. Make temporary marks on elbow connection 1. Ensure that all components are free from wear,
(14) and engine oil filter base (4) for damage, and restriction. Replace any component
installation purposes. that is worn, damaged, or not free from restriction.
f. Loosen locking nut (21) and remove elbow
connection (14). Remove O-ring seal (23).
44 UENR4511-01
e. Tighten plug (28) and plug (15) to a torque of

55 N·m (41 lb ft).
f. Install a new O-ring seal (24) to adapter (20).

Install the adapter from engine oil filter base
(4). Tighten the adapter to a torque of 20 N·m
(177 lb in).
g. Install a new O-ring seal (11) to elbow

connection (10). Install elbow connection to
adapter (20) and align to temporary marks.
Tighten locking nut (17) to a torque of 40 N·m
(30 lb ft). Use a suitable tool to hold the elbow
connection as the locking nut is tightened.
Ensure that the elbow connection is still
aligned to the temporary marks.
h. Install a new O-ring seal (18) to valve (12).

Install the valve to elbow connection (10).
Tighten the valve to a torque of 25 N·m
(221 lb in).
i. Install cap (13) to valve (12).
j. Install a new O-ring seal (23) to elbow

connection (14). Install the elbow connection
to engine oil filter base (4) and align temporary
Illustration 69 g03777625 marks. Tighten locking nut (21) to a torque of
80 N·m (59 lb ft). Use a suitable tool to hold
2. If necessary, follow Step 2.a through Step 2.j in the elbow connection as the locking nut is
order to assemble engine oil filter base (4). tightened. Ensure that the elbow connection is
still aligned to the temporary marks.

equipment.
Follow the recommended procedure and use
all recommended tooling to release the spring
force.
a. Install valve (22) and spring (19) to engine oil

filter base (4). Ensure that the valve is free to
move in the engine oil filter base.
b. Install a new O-ring seal (16) to plug (15).

Install the plug to engine oil filter base (4) hand
tight.
c. Install valve (25) and spring (26) to engine oil

filter base (4). Ensure that the valve is free to
move in the engine oil filter base.
d. Install a new O-ring seal (27) to plug (28).

Install the plug to engine oil filter base (4) hand
tight.
UENR4511-01 45
3. Install Tooling (A) in position (X) in the cylinder
block.
4. Position a new gasket (8) onto the cylinder block.
Ensure that the gasket is correctly orientated.
5. Install oil cooler core (9) to the cylinder block.
6. Install a new gasket (6) (not shown) and ensure
that the gasket is correctly orientated. Install
engine oil filter base (4) and install bolts (5) hand
tight.
7. Remove Tooling (A) from the cylinder block. Install
remaining bolts (5) hand tight.
8. Tighten bolts (5) to a torque of 28 N·m (248 lb in)
in the numerical sequence that is shown in
Illustration 72 .
46 UENR4511-01
Start By:
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, “Engine Oil Pan -
NOTICE
component life.
NOTICE
and mandates.
9. Install a new oil filter (5) to engine oil filter base (4)
10. Install a new O-ring seal (2) (not shown) to elbow
connection (3). Connect hose assembly (1) to
elbow connection (3). Tighten the tube nut for the
hose assembly to a torque of 80 N·m (59 lb ft).
Use a suitable tool to hold the elbow connection as
the tube nut is tightened.
11. Fill the engine with coolant to the correct level.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change”.
i05986424
Engine Oil Pump - Remove
1. Remove bolts (3) from suction pipe (4). Remove
the suction pipe from the engine oil pump (1).
Removal Procedure 2. Remove gasket (2) (not shown).

Table 15 3. Remove bolts (6) and bolts (7) from tube assembly
Required Tools (9). Remove the tube assembly from engine oil
pump (1) and the cylinder block.
A 27610275 Driver Gp 1
UENR4511-01 47
c. Remove idler gear (15) from engine oil pump

(1).
d. Remove idler hub (12) from engine oil pump

(1).
order to remove bushing (13) from idler gear (14).
a. Place idler gear (14) on a suitable support.
b. Use Tooling (A) and a suitable press to

remove bushing (13) from idler gear (14).
i05986422
Engine Oil Pump -

Disassemble
Illustration 75 g03779763 Disassembly Procedure

Table 16
5. Remove bolts (10) from engine oil pump (1).
Remove the engine oil pump from the cylinder Required Tools
block. Tool Part Number Part Description Qty
6. If necessary, remove ring dowel (11) (not shown). A 27610275 Driver Gp 1
B - Combination Puller 1
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove” for the correct procedure.
NOTICE
component life.
NOTICE
and mandates.
order to disassemble engine oil pump (1).
a. Place engine oil pump (1) in a suitable

support.
b. Remove Allen head bolt (15) and the washer

from engine oil pump (1).
48 UENR4511-01
1. Remove bolt (5) and the washer from idler gear 5. Remove bolts (9) from front cover (10). Remove
(4). Remove the idle gear from idler hub (2). the front cover from the body of engine oil pump
(1).
2. Remove idler hub (2) from engine oil pump (1).
3. Use Tooling (B) to remove drive gear (6). NOTICE
Before removing the drive shaft from the pump hous-
4. If necessary, follow Step 4.a through Step 4.b in ing, be sure that no burrs exist on the drive shaft. If
order to remove bushing (3) from idler gear (4). the drive shaft has burrs on it, the bores in the pump
housing may be scratched.
b. Use Tooling (A) and a suitable press to 6. Remove inner rotor (8) from the body of engine oil
remove bushing (3) from idler gear (4). pump (1).
7. Remove outer rotor (8) from the body of engine oil
pump (1).
8. Remove shaft assembly (8) and shaft assembly
(11) from oil pump body (9).
UENR4511-01 49
NOTICE
component life.
1. Ensure that all of the parts of the engine oil pump

are thoroughly clean prior to assembly. Lubricate
all internal parts of the engine oil pump with
clean engine oil.
9. Position engine oil pump (1) into a suitable

support.
Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
10. Remove plug (13) from engine oil pump (1). As Improper assembly of parts that are spring
the plug is removed from the engine oil pump, the loaded can cause bodily injury.
spring force will be released.
11. Remove spring (13) and oil pressure relief assembly procedure and wear protective
plunger (12) from engine oil pump (1). equipment.
i05986421 2. Position engine oil pump (1) into a suitable

support.
Engine Oil Pump - Assemble 3. Install oil pressure relief plunger (12) into engine oil
pump (1). Ensure that the oil pressure relief
plunger is free to move in the bore of the engine oil
pump.
Assembly Procedure
Table 17
4. Install spring (13) into oil pressure relief plunger
(12). Ensure that the spring is correctly located
Required Tools
into oil pressure relief plunger.
5. Install plug (13) to engine oil pump (1) hand tight.
6. Tighten plug (13) to a torque of 70 N·m (52 lb ft).
50 UENR4511-01
b. Position engine oil pump (1) onto a suitable

press and a suitable surface with the shaft of
inner rotor in the vertical position. Ensure that
inner rotor (8) is correctly supported.
c. Position drive gear (6) onto the shaft of inner

rotor (8). Use the suitable press in order to
press the drive gear flush with the end of the
shaft of inner rotor (8). Ensure that the inner
rotor is free to turn and has the correct end
clearance.
order to install bushing (3) to idler gear (4).
b. Use Tooling (A) and a suitable press to install

bushing (3) to idler gear (4). Install the bearing
so the distance between the hub bolt face of
the idler gear and the bearing is
Illustration 81 g03779791 0.75 ± 0.25 mm (0.030 ± 0.010 inch).
9. Install idler hub (2) into engine oil pump (1).
Ensure that the idler hub is correctly located into
the engine oil pump.
10. Install idler gear (4) to engine oil pump (1).
Ensure that the idler gear is correctly orientated
onto idler hub (2).
11. Install Allen head bolt (5) and the washer to
engine oil pump (1). Tighten the bolt to a torque of
55 N·m (41 lb ft).
12. Install outer rotor (8) to the body of engine oil
pump (1).
13. Install front cover (10) to the body of engine oil
pump (1). Ensure that the front cover is correctly
orientated onto the engine oil pump.
14. Install bolts (9) to front cover (1). Tighten the bolts
to a torque of 28 N·m (248 lb in).
7. Follow Step 7.a through Step 7.c in order to install

drive gear (6) to the shaft of inner rotor (8).
NOTICE
Before removing the drive shaft from the pump hous-
ing, be sure that no burrs exist on the drive shaft. If
the drive shaft has burrs on it, the bores in the pump
housing may be scratched.
a. Install inner rotor (8) to the body of engine oil

pump (1).
UENR4511-01 51
End By: bushing is correctly located into the idler gear.

a. Install the engine oil pump. Refer to 3. If necessary, follow Step 3.a through Step 3.d in
Disassembly and Assembly, “Engine Oil Pump order to assemble engine oil pump (1).
- Install” for the correct procedure.
a. Place engine oil pump (1) into a suitable
i05986423 support.
Engine Oil Pump - Install b. Install idler hub (12) into engine oil pump (1).
Ensure that the idler hub is correctly located
into the engine oil pump.
Installation Procedure c. Install idler gear (15) to engine oil pump (1).
Ensure that the idler gear is correctly
Table 18
orientated onto idler hub (12).
Required Tools
d. Install Allen head bolt (15) and the washer to
engine oil pump (1). Tighten the bolt to a
A 27610275 Driver Gp 1 torque of 55 N·m (41 lb ft).
NOTICE
component life.
1. Ensure that all components of the engine oil pump

are free from wear or damage. Replace any
component that is worn or damaged.
4. If necessary, install ring dowel (11) (not shown).

5. Install engine oil pump (1) onto the cylinder block.
Ensure that ring dowel (11) (not shown) is correctly
located into the cylinder block.
6. Install bolts (10) to engine oil pump (1). Tighten the
bolts to a torque of 55 N·m (41 lb ft).


bushing (13) to idler gear (14). Ensure that the
52 UENR4511-01
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
i06542515
Water Pump - Remove

Removal Procedure
Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
Illustration 85 g03779762 steam. Any contact can cause severe burns.
7. Install new O-ring seal (5) (not shown) and O-ring Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
seal (8) (not shown) into the recess of tube cooling system pressure cap is cool enough to
assembly (9). Ensure that the O-rings are correctly touch with your bare hand.
located into the recess of the tube assembly.
Do not attempt to tighten hose connections when
8. Install tube assembly (9) engine oil pump (1) and the coolant is hot, the hose can come off causing
the cylinder block. burns.
9. Install bolts (6) and bolts (7) to tube assembly (9). Cooling System Coolant Additive contains alkali.
Tighten the bolts hand tight. Avoid contact with skin and eyes.
10. Tighten bolts (6) and bolts (7) to a torque of
55 N·m (41 lb ft). Ensure that the tube assembly is NOTICE
not strained as the bolts are tightened. Care must be taken to ensure that fluids are con-
11. Position a new gasket (2) (not shown) onto nance, testing, adjusting and repair of the product.
suction pipe (4). Position the suction pipe onto Be prepared to collect the fluid with suitable contain-
engine oil pump (1) and install bolts (3) hand tight. ers before opening any compartment or disassem-
12. Tighten bolts (3) to a torque of 55 N·m (41 lb ft).
Ensure that the suction pipe is not strained as the Dispose of all fluids according to local regulations
bolts are tightened. and mandates.
NOTICE
component life.
UENR4511-01 53
Start By:
a. Drain the coolant from the cooling system into
a suitable container for storage or disposal.
“Cooling System Coolant (ELC) - Change” for
the correct procedure.
b. Remove the alternator bracket. Refer to
Disassembly and Assembly, “Alternator -
c. Remove the V-belt from the water pump. Refer
to Disassembly and Assembly, “V- Belts -
Remove and Install (Water Pump Drive Belt)”
or refer to Disassembly and Assembly,
“Alternator Belt - Remove and Install” for the
correct procedure.
Removal Procedure
2. Loosen hose clamp (5) for hose assembly (4).

3. Remove bolts (6) from water pump (3). Support the
water pump as the bolts are removed.
4. Remove water pump (3) from hose assembly (4)
and the cylinder block.
i05986475
Water Pump - Disassemble
Illustration 86 g06015537 Disassembly Procedure

Typical example Table 19
Required Tools
1. Loosen hose clamp (1) and disconnect hose
assembly (2) from the water pump elbow Tool Part Number Part Description Qty
connection. A 27610275 Driver Gp 1
54 UENR4511-01
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove” for the
correct procedure.
NOTICE
and mandates.
NOTICE
component life.
6. Use Tooling (A) and a suitable press in order to

remove impeller (10) from shaft assembly (12).
7. Use Tooling (A) and a suitable press in order to
remove shaft assembly (12) from water pump
housing (4).
8. Use Tooling (A) to remove seal (11) from water
pump housing (4).
9. Use Tooling (A) to remove hub (13) from shaft
assembly (12).
i05986474
Water Pump - Assemble
Assembly Procedure
Table 20
Required Tools
1. Remove bolts (1) from cover (2). Tool Part Number Part Description Qty
2. Remove cover (2) and gasket (3) from water pump A 27610275 Driver Gp 1
(4).
B T401071 Seal Driver 1
3. Use a suitable tool to hold pulley (5) and remove
bolts (6). Remove the pulley from the water pump
(4). NOTICE
4. Remove bolts (7) and remove inlet elbow (8) from
water pump (4). Contaminants may cause rapid wear and shortened
component life.
5. Remove gasket (8) (not shown).
UENR4511-01 55
1. Use Tooling (A) and a suitable press in order to 5. Position a new gasket (9) (not shown) onto inlet
install shaft assembly (12) in water pump housing elbow (8). Ensure that the gasket is correctly
(4). After installation, the bearing on the shaft orientated onto the inlet elbow.
assembly should be flush with the face of the
6. Install inlet elbow (8) to water pump housing (4).
water pump housing. Refer to Specifications,
Install bolts (7) to the inlet elbow. Ensure that the
“Water Pump” for further information.
inlet elbow is correctly orientated.
2. Use Tooling (B) to install seal (11) over shaft
7. Tighten bolts (7) to a torque of 28 N·m (248 lb in).
assembly (12) and into water pump housing (4).
Install the seal to the correct working height. Refer 8. Position a new gasket (3) onto cover (2). Ensure
to Specifications, “Water Pump” for the correct that the gasket is correctly orientated onto the
working height. cover.
3. Use Tooling (A) and a suitable press in order to 9. Position cover (2) onto water pump housing (4).
install impeller (10) onto shaft assembly (12). Install bolts (1) to the cover. Hand tighten the bolts
Install the impeller until the distance between the and ensure that the bolt holes for the water pump
impeller and the machined surface of the water retaining bolts are correctly aligned.
pump housing is 0.75 ± 0.25 mm
(0.030 ± 0.010 inch). Refer to Specifications,
.
“Water Pump” for further information.
11. Install pulley (5) to the water pump (4). Install
4. Use Tooling (A) to install hub (13) to shaft
bolts (6) to the pulley.
assembly (12). Install the hub to the correct
distance from the front of the hub to water pump 12. Use a suitable tool to hold pulley (5) and tighten
housing (8). Refer to Specifications, “Water Pump” bolts (6) to a torque of 28 N·m (248 lb in).
for the correct distance.
56 UENR4511-01
End By: 6. Tighten hose clamp (5) for hose assembly (4) to a
torque of 7 N·m (62 lb in).
a. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Install” for the
correct procedure.
i06542542
Water Pump - Install

NOTICE
component life.
1. Ensure that all components of the water pump and

the cylinder block are clean and free from wear or
damage.
Typical example
7. Connect hose assembly (2) to the water pump

elbow connection. Tighten hose clamp (1) to a
2. Install a new O-ring seal (7) (not shown) and a new

O-ring seal (8) (not shown) to water pump (5).
Ensure that the O-ring seals are correctly located
into the recess of the water pump.
3. Install water pump (3) to hose assembly (4) and
the cylinder block. Ensure that the O-ring seals are
not damaged or dislodged from the recess of the
water pump.
4. Install bolts (6) to water pump (3). Support the
water pump as the bolts are installed.
UENR4511-01 57
End By:
NOTICE
a. Install the V-belt to the water pump. Refer to Care must be taken to ensure that fluids are con-
Disassembly and Assembly, “V- Belts - nance, testing, adjusting and repair of the product.
Remove and Install (Water Pump Drive Belt)” Be prepared to collect the fluid with suitable contain-
or refer to Disassembly and Assembly, ers before opening any compartment or disassem-
“Alternator Belt - Remove and Install” for the bling any component containing fluids.
correct procedure.
b. Install the alternator bracket . Refer to Dispose of all fluids according to local regulations
Disassembly and Assembly, “Alternator - and mandates.
c. Fill the cooling system with coolant. Refer to 1. Drain the coolant from the cooling system into a
Operation and Maintenance Manual, “Cooling suitable container for storage or disposal. Refer to
System Coolant (ELC) - Change” and Operation and Maintenance Manual, “Cooling
Operation and Maintenance Manual, System Coolant (ELC) - Change”.
“Capacities (Refill)”.
i05986893
Water Temperature Regulator -

Remove and Install
Removal Procedure
Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and Illustration 94 g03783784
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when Disconnect the hose assembly from water
the coolant is hot, the hose can come off causing temperature regulator housing (4).
burns.
Cooling System Coolant Additive contains alkali. Ensure that the hose clamp is sufficiently loosened
Avoid contact with skin and eyes. in order to allow hose to disconnected from water
temperature regulator housing (4).
NOTICE 4. Remove bolts (3) from water temperature regulator
Keep all parts clean from contaminants. housing (4). Support the water temperature
regulator housing as the bolts are removed.
component life. 5. Remove water temperature regulator housing (4)
from the cylinder head.
58 UENR4511-01
c. Remove adapter (10) from water temperature

regulator housing (4).
d. Remove O-ring seal (8) (not shown).
Table 21
Required Tools
A 27610309 Seal Installer 1
NOTICE
component life.
1. Clean the gasket surfaces of the water

temperature regulator housings and the cylinder
head. Ensure that all components are free from
wear or damage. Replace any component that is
worn or damaged.
2. Check the water temperature regulator for correct
operation. Refer to System Operation, Testing and
Adjusting, “Water Temperature Regulator - Test”
for the correct procedure to test the water
temperature regulator.
7. Remove water temperature regulator (12) from

water temperature regulator housing (4).
8. Use a suitable tool to remove seal (13) from water
temperature regulator housing (4). Care should be
taken not to damage the water temperature
regulator housing.
to remove valve (11) and adapter (10).
a. Remove cap (9) from valve (11).
b. Remove valve (11) from adapter (10).
UENR4511-01 59
4. Use Tooling (A) to install a new seal (13) to water

temperature regulator housing (4). Ensure that the
seal is installed in the correct orientation.
5. Apply glycerin to new seal (13).
6. Install water temperature regulator (12) to water
7. Ensure that hose clamp (5) is correctly positioned

onto hose assembly.
8. Position gasket (7) (not shown) onto water
9. Position water temperature regulator housing (4)
onto the cylinder head and install bolts (3) to the
water temperature regulator housing. Support the
water temperature regulator housing as the bolts
are installed.
Note: Ensure that the water temperature regulator

housing is correctly located onto the hose assembly.
11. Tighten hose clamp (5) for hose assembly (6) to a
order to install adapter (10) and valve (11).
a. Install a new O-ring seal (8) (not shown) to 12. Connect hose assembly (1) to water temperature
adapter (10). regulator housing (4). Tighten hose clamp (5) to a
b. Install adapter (10) to water temperature
regulator housing (4). Tighten the adapter to a
c. Install valve (11) to adapter (10). Tighten the

valve to a torque of 25 N·m (221.26875 lb in).
d. Install cap (9) to valve (11).
60 UENR4511-01
13. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant (ELC) - Change” and Operation
and Maintenance Manual, “Capacities (Refill)”.
i06548014
Engine Lifting Bracket -

Remove and Install
Start By
Start By:
a. Remove the alternator and the alternator
bracket. Refer to Disassembly and Assembly,
Alternator - Remove and Install for the correct
procedure.
b. Remove the belt tensioner. Refer to
Disassembly and Assembly, Belt Tensioner - Illustration 101 g06019376
Remove and Install for the correct procedure.
2. Follow step 2.a through step 2.d to remove the
c. Remove the idler pulley. Refer to Disassembly front engine lifting bracket.
and Assembly, Idler Pulley - Remove and
Install for the correct procedure. a. Remove bolts (6) and washers (5) from
bracket (4).
Removal Procedure
b. Remove bracket (4)

1. Follow step 1.a through step 1.b to remove rear

engine lifting bracket (1). c. Remove bolts (9) and washers (8) from
bracket (7).
a. Remove bolts (3) and washers (2) from
bracket (1). Support the weight of bracket (7) as the bolts
are removed.
b. Remove bracket (1). d. Remove bracket (7).
UENR4511-01 61
1. Follow step 1.b through step 1.c to install rear
engine lifting bracket (1).
a. Position bracket (1) to the cylinder head.
b. Install bolts (3) and washers (2) to bracket (1).
c. Tighten bolts (3) to a torque of 100 N·m

(74 lb ft).
2.
a. Position bracket (7) to the cylinder head.
b. Install bolts (9) and washers (8) finger tight.
c. Position bracket (4) to bracket (7) and the

water temperature regulator housing.
d. Install bolts (6) and washers (5) to bracket (4).
e. Tighten bolts (9) to a torque of 55 N·m

(41 lb ft).
f. Tighten bolts (6) to a torque of 55 N·m

(41 lb ft).
62 UENR4511-01
End By:
a. Install the idler pulley. Refer to Disassembly
and Assembly, Idler Pulley - Remove and
Install for the correct procedure.
b. Install the belt tensioner. Refer to Disassembly
and Assembly, Belt Tensioner - Remove and
Install for the correct procedure.
c. Install the alternator and the alternator bracket.
Refer to Disassembly and Assembly,
Alternator - Remove and Install for the correct
procedure.
i05986259
Engine Support (Front) -

Remove and Install
Removal Procedure
Table 22
Required Tools

Guide Studs
A - 2 Illustration 106 g03780280
(1/2 - 13 UNC by 6 inch)
1. If necessary, remove tube assembly (3), tube

NOTICE assembly (6), guards (2), radiator supports (1),
Care must be taken to ensure that fluids are con- radiator assembly (5) and coolant tube assemblies
tained during performance of inspection, mainte- and radiator support brackets (4) in order to
Be prepared to collect the fluid with suitable contain- access engine support front. Refer to the Original
ers before opening any compartment or disassem- Equipment Manufacture (OEM) for the correct
bling any component containing fluids. removal procedure.
Dispose of all fluids according to local regulations 2. Remove the assembly of the vibration damper and
and mandates. the crankshaft pulley. Refer to Disassembly and
Assembly, “Vibration Damper and Pulley -
NOTICE
component life.
UENR4511-01 63
3. Use a suitable lifting device to support the engine

in order to remove engine support (8). The weight
of the engine is approximately 1202 kg (2650 lb).
4. Remove bolts (7) from Position (X). Install Tooling
(A).
5. Remove remaining bolts (7).
6. Remove engine support (8) from the cylinder
block. The weight of the engine support is
approximately 33.5 kg (74 lb).
Table 23
Required Tools

Guide Studs
A - 2
(1/2 - 13 UNC by 6 inch)

NOTICE
Keep all parts clean from contaminants. Tightening sequence
Contaminants may cause rapid wear and shortened 2. Use a suitable lifting device to support the engine
component life. in order to install engine support (8). The weight of
the engine is approximately 1202 kg (2650 lb).
1. Ensure that all components of the engine support 3. Install Tooling (A) into Position (X).
are free from wear or damage. Place any
component that is worn or damaged. 4. Install engine support (8) onto the cylinder block.
The weight of the engine support is approximately
33.5 kg (74 lb).
5. Install bolts (7) hand tight.
64 UENR4511-01
6. Remove Tooling (A) and install remaining bolts (7).

Tighten the bolts to a torque of 105 N·m (77 lb ft)
in the order that is shown in Illustration 109 .
7. Install the assembly of the vibration damper and
the crankshaft pulley. Refer to Disassembly and
8. If necessary, install tube assembly (3), tube

assembly (6), guards (2), radiator supports (1),
radiator assembly (5) and coolant tube assemblies
and radiator support brackets (4) in order to
access engine support front. Refer to the OEM for
the correct removal procedure.
i06548084
Engine Support (Front) -

Remove and Install
(Option 2)
Removal Procedure
NOTICE
and mandates.
UENR4511-01 65
NOTICE
component life.
2. Use a suitable lifting device to support the engine

to install engine support brackets (2). The weight
of the engine is approximately 1202 kg (2650 lb).
3. Position engine support bracket (2) onto the
Illustration 111 g06019409 cylinder block.
1. Use a suitable lifting device to support the engine 4. Install new bolts (1). Tighten bolts (1) to a torque of
to remove engine support brackets (2). The weight 240 N·m (177 lb ft)
of the engine is approximately 1202 kg (2650 lb). 5. Repeat step 2 through step 4 to install the other
2. Remove bolts (1) from engine support bracket (2). engine support bracket.
3. Remove engine support bracket (2) from the i05986278
cylinder block.
4. Repeat step 2 through step 3 to remove the other Flywheel - Remove
engine support bracket.
Removal Procedure
NOTICE Table 24
Required Tools
component life. Tool Part Number Part Description Qty
Guide Stud
A - 2
M16 x 2 by 12inch
1. Ensure that the engine support brackets are free
from wear or damage. Replace any component
that is worn or damaged.
66 UENR4511-01
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install” for the correct
procedure.
NOTICE
component life.

Typical example
5. Inspect flywheel (2) and ring gear (3) for wear or

damage. Replace any components that are worn
or damaged.
6. To remove the flywheel ring gear, follow Steps 6.a
and 6.b.
a. Place the assembly of flywheel (2) on a
suitable support.
Illustration 113 g03794642 Note: Identify the orientation of the teeth on the
Typical example flywheel ring gear.
1. Use a suitable tool to lock the flywheel. Loosen b. Use a hammer and a punch in order to remove
bolts (1). ring gear (3) from flywheel (2).
2. Attach a suitable lifting device to flywheel (2).
i05986277
Support the weight of the flywheel. The weight of
the flywheel is approximately 50 kg (110 lb). Flywheel - Install
3. Remove two bolts (1). Install Tooling (A).
4. Remove the remaining bolts (1). Use the lifting
device in order to remove flywheel (2). Installation Procedure
Table 25
Required Tools

Guide Stud
A - 2
M16 x 2 by 12 inch
B - Loctite 242 1
UENR4511-01 67
2. Inspect the crankshaft rear seal for leaks. If there

NOTICE
Keep all parts clean from contaminants. are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Contaminants may cause rapid wear and shortened Rear Seal - Remove” for the correct procedure.
component life.

Typical example
Typical example 3. Install a suitable lifting device to flywheel (2). The
weight of the flywheel is approximately 31 kg
(68 lb).
Always wear protective gloves when handling 4. Install Tooling (A) on the crankshaft.
parts that have been heated. 5. Align the arrows on flywheel (2) and the
crankshaft. Use the lifting device in order to
1. If flywheel ring gear (3) was removed, follow Steps position the flywheel onto Tooling (A).
1.a through 1.c in order to install a new ring gear to
flywheel (2). 6. Apply Tooling (B) to the threads of new bolts (1).
a. Identify the orientation of the teeth on the new 7. Install bolts (1). Remove Tooling (A). Install
ring gear (3). remaining bolts (1).
8. Use a suitable tool to prevent the flywheel from
Note: The chamfered side of the ring gear teeth
rotating. Tighten bolts (1) to a torque of 300 N·m
must face toward the starting motor when the
flywheel is installed. The chamfered side of the ring (221 lb ft).
gear teeth will ensure the correct engagement of 9. Remove the lifting device from flywheel (1).
the starting motor.
10. Check the run out of the flywheel. Refer to
b. Heat flywheel ring gear (3) in an oven to a Systems Operations, Testing and Adjusting,
maximum temperature of 316 °C (600 °F) “Flywheel - Inspect” for the correct procedure.
prior to installation.
Note: Do not use a torch to heat the ring gear.
c. Ensure that the orientation of ring gear (3) is

correct and quickly install the ring gear onto
flywheel (2).
68 UENR4511-01
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
procedure.
i05986493
Crankshaft Rear Seal -

Remove
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly
and Assembly, “Flywheel - Remove” for the
correct procedure.
NOTICE
and mandates. 1. Remove the bolts and washers (1) from crankshaft
rear seal (4).
NOTICE 2. Remove crankshaft rear seal (4) from crankshaft
Keep all parts clean from contaminants. (2) and flywheel housing (3).
Contaminants may cause rapid wear and shortened 3. Remove O-ring seal (5).
component life.
4. If the crankshaft is installed with a crankshaft wear
sleeve, use a suitable tool in order to remove the
crankshaft wear sleeve from the crankshaft.
Ensure that the crankshaft and the flywheel
housing are not damaged.
i05986469
Crankshaft Rear Seal - Install

NOTICE
component life.
UENR4511-01 69
Note: If the crankshaft rear seal, O-ring seal, and the

shipping sleeve are separated, these components
should not be used.
1. Lubricate O-ring seal (5) with clean engine oil.

Install the O-ring seal to crankshaft rear seal (4).
2. Position crankshaft rear seal (4) and the shipping
sleeve over crankshaft (2). Push the crankshaft
rear seal into place. Pushing the crankshaft rear
seal into place will dislodge the shipping sleeve.
Do not remove the shipping sleeve until bolts
(1) are installed.
3. Install new bolts and washers (1) hand tight.
in numerical sequence, shown in Illustration 119 .
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install” for the correct
procedure.
i05986311
Flywheel Housing - Remove

and Install
Removal Procedure
Table 26
Required Tools
Guide Studs
A - 2
M12 x 1.75 by 5 inches

Tightening sequence for the bolts
Note: Leave the shipping sleeve in place to install the

crankshaft rear seal. The crankshaft rear seal must
be installed dry.
70 UENR4511-01
Start By: 2. Remove crankshaft rear seal (3). Refer to

Disassembly and Assembly, “Crankshaft Rear
a. Remove the engine oil pan. Refer to Seal - Remove” for the correct procedure.
Remove and Install” for the correct procedure. 3. Attach a suitable lifting device to flywheel housing
(2). The weight of flywheel housing (1) is
b. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting approximately 25 kg (55 lb).
Motor - Remove and Install” for the correct 4. Remove bolts (1) from Positions (X). Install Tooling
procedure.
(A) to Positions (X).
c. Remove the flywheel. Refer to Disassembly
and Assembly, “Flywheel - Remove and 5. Remove the remaining bolts (1). Use the lifting
Install” for the correct procedure. device to remove flywheel housing (2) from the
cylinder block.
NOTICE 6. Inspect the dowels in the cylinder block. Do not
tained during performance of inspection, mainte- remove the dowels unless the dowels are
nance, testing, adjusting and repair of the product. damaged.
ers before opening any compartment or disassem- Installation Procedure
bling any component containing fluids. Table 27
Dispose of all fluids according to local regulations Required Tools
and mandates.
Guide Bolts
A - 2
NOTICE M12 x 1.75 by 5 inches
B CH10879 Sealant 1
component life.
NOTICE
1. Use a suitable lifting device and cribbing to support
the rear of the engine. Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the mating surfaces of the flywheel

housing and the cylinder block are clean and free
from damage.

Typical example
UENR4511-01 71

Typical example

Tightening sequence for flywheel housing bolts
2. Apply Tooling (B) to the rear face of the cylinder

block. Ref to Illustration 122 for the correct
application position.
Note: The flywheel housing must be installed within

10 minutes of applying Tooling (B).
3. Install Tooling (A) to Positions (X) in the cylinder

block.
4. Attach a suitable lifting device to flywheel housing
(2). The weight of the flywheel housing is
72 UENR4511-01
5. Use the lifting device to align flywheel housing (2)

with Tooling (A).
6. Install flywheel housing (2) to the cylinder block.
7. Install bolts (1). Remove Tooling (A). Install the
remaining bolts.
Tighten the bolts in the sequence that is shown in
Illustration 123 .
9. Install crankshaft rear seal (3). Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Install” for the correct procedure.
10. Use a suitable lifting device to raise the rear of
the engine and remove cribbing.
End By:
b. Install the flywheel. Refer to Disassembly and Typical example
Assembly, “Flywheel - Remove and Install” for
the correct procedure. 1. Use a suitable tool to prevent the crankshaft from
c. Install the electric starting motor. Refer to turning. Remove bolts (1) and thrust block (2) from
Disassembly and Assembly, “Electric Starting the assembly of crankshaft vibration damper (3).
procedure. 2. Attach a suitable lifting device to the assembly of
crankshaft vibration damper (3). Remove the
i06542630 assembly of crankshaft vibration damper. The
weight of the assembly of crankshaft vibration
Vibration Damper and Pulley - damper is approximately 50 kg (110 lb).
3. Remove the crankshaft front seal. Refer to
Remove and Install Disassembly and Assembly, “Crankshaft Front
Seal - Remove” for the correct procedure.
Start By:
a. Remove the v-belts. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install” and
refer to Disassembly and Assembly,
“Alternator Belt - Remove and Install” for the
correct procedure.
Removal Procedure
NOTICE
component life.
UENR4511-01 73

Typical example Typical example
4. If necessary, follow Step 4.a through Step 4.c to 2. If necessary, follow Step 2.a through Step 2.c to
disassemble the assembly of crankshaft vibration assemble the assembly of crankshaft vibration
damper (3). damper (3).
a. Place the assembly of crankshaft vibration a. Place adapter (7) in a suitable support.
damper (5) in a suitable support.
b. Install damper (6) and pulley (7) onto adapter
b. Remove bolts (4). (7). Align the bolt hole in the damper and the
pulley.
c. Remove pulley (5), damper (6) from adapter
(7). c. Install bolts (4). Tighten the bolts to a torque of
55 N·m (41 lb ft).
NOTICE
component life.
NOTICE
Thoroughly inspect the viscous damper for signs of
leakage or for signs of a dented or damaged to the
case. Either of these conditions can cause the weight
to contact with the case. The weight contacting with
the case can affect the viscous damper operation.
1. Ensure that all the components of the assembly of

the crankshaft vibration damper are free from wear
or damage. Replace any component that is worn
or damaged.

Typical example
74 UENR4511-01
3. Install a new crankshaft front seal. Refer to Start By:

Disassembly and Assembly, “Crankshaft Front
Seal - Install” for the correct procedure. a. Remove the assembly of the vibration damper
and the pulley. Refer to Disassembly and
4. Attach a suitable lifting device to the assembly of Assembly, “Vibration Damper and Pulley -
crankshaft vibration damper (3). Install the Remove and Install” for the correct procedure.
assembly of crankshaft vibration damper. The
weight of the assembly of crankshaft vibration NOTICE
damper is approximately 50 kg (110 lb). Ensure tained during performance of inspection, mainte-
that the crankshaft front seal is not damaged nance, testing, adjusting and repair of the product.
as the assembly of crankshaft vibration Be prepared to collect the fluid with suitable contain-
damper in installed. ers before opening any compartment or disassem-
5. Install thrust block (2) and bolts (1) to the assembly
of crankshaft vibration damper (3). Hand tighten Dispose of all fluids according to local regulations
and mandates.
the bolts.
6. Use a suitable tool to prevent the crankshaft from
turning and tighten bolts (1) to a torque of 160 N·m NOTICE
(118 lb ft). Keep all parts clean from contaminants.
End By: Contaminants may cause rapid wear and shortened

component life.
a. Install the v-belts . Refer to Disassembly and
Assembly, “V-Belts - Remove and Install
(Charging Alternator Drive Belts)” and refer to
Disassembly and Assembly, “Alternator Belt -
i05986329
Crankshaft Front Seal -

Remove
Removal Procedure
Table 28
Required Tools
A 27610311 Slide Hammer Puller 1
B - Drill Bit3 mm (0.118 inch) 1
1. Apply clean grease to Tooling (B) in order to

prevent any swarf that is generated from entering
the engine. Carefully use Tooling (B) to drill three
evenly spaced holes in crankshaft front seal (1).
Note: Ensure that the housing or the crankshaft is
not damaged when drilling the front seal.
UENR4511-01 75
2. Alternate between the drilled holes and use End By:

Tooling (A) to remove crankshaft front seal (1).
a. Install the assembly of the vibration damper
and the pulley. Refer to Disassembly and
i05986328
Crankshaft Front Seal - Install
i05975647
Front Cover - Remove

Table 29 Removal Procedure
Required Tools
C T401072 Front Seal Installer 1 NOTICE

NOTICE Be prepared to collect the fluid with suitable contain-
Contaminants may cause rapid wear and shortened bling any component containing fluids.
component life.
and mandates.
NOTICE
component life.
1. Ensure that the housing is clean, dry, and free from

damage.
2. Use Tooling (C) and install crankshaft front seal
(1).
Note: Do not lubricate the seal. The seal must be
installed dry.
76 UENR4511-01
1. Remove the nuts and bolts (3) and remove

blanking plate (5).
2. Remove bolts (1) from front cover (2). Identify the
positions of bolts of different length. Support the
front cover as the bolts are removed.
3. Remove front cover (2) and gasket (4) (not
shown).
i05975648
Front Cover - Install

NOTICE
component life. Illustration 132 g03781238
1. Ensure that all components are free from wear or

is worn or damaged.
UENR4511-01 77
Start By:
a. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
NOTICE
and mandates.
NOTICE
Illustration 133 g03781240 component life.
Front cover tightening sequence
1. Set the No. 1 piston to top center on the
2. Clean the gasket surfaces of the front housing (6), compression stroke. Refer to Testing and
front cover (2), and blanking plate (5). Adjusting, “Finding Top Center Position for No. 1
3. Position a new gasket (4) (not shown) onto front Piston” for the correct procedure.
cover (2).
4. Install front cover (2) and in stall bolts (1). Support
the front cover as the bolts are installed.
5. Apply Tooling (B) to front housing (6) as shown in
Illustration 132 .
6. Install blanking plate (5) onto front housing (6).
Install the nuts and bolts (3) hand tight.
7. Tighten bolts (1) for front cover (2) to a torque of
28 N·m (248 lb in) in the tightening sequence
shown in Illustration 133 .
8. Tighten the nuts and bolts (3) for blanking plate (5)
to a toque of 100 N·m (74 lb ft).
i05986299
Gear Group (Front) - Remove
Removal Procedure
Table 30
Required Tools
78 UENR4511-01
5. If necessary, remove engine oil pump idler gear

(5). Refer to Disassembly and Assembly, “Engine
Oil Pump - Remove” for the correct procedure.
6. Remove thrust plate (9) from idler hub (9). Remove
idler gear (6) from idler hub (9).
order to remove bushing (8) from idler gear (7).
b. Use Tooling (A) and a suitable press to

remove bushing (8) from idler gear (7).
8. If necessary, remove crankshaft gear (5). Refer to
Disassembly and Assembly, “Crankshaft Gear -
i05986298
Gear Group (Front) - Install
Table 31
Required Tools
NOTICE
component life.
1. Ensure that all components of the gear group are

free from wear or damage. Refer to Specifications,
“Gear Group (Front)” for the correct information.
Replace any component that is not within
specification.
2. Make temporary mark on each of idler gear (4) and

crankshaft gear (5) for installation purposes.
3. Remove bolts (1) and bolt (2). Remove retaining
plate (3).
4. Remove idler gear assembly (4) from the cylinder
block.
UENR4511-01 79
bushing is correctly located into the idler gear.

3. If necessary, install crankshaft gear (5). Refer to
Remove and Install” for the correct procedure
4. Install idler gear (7) to idler hub (9). Ensure that the
idler gear is correctly orientated in the idler hub.
Note: Ensure that the idler gear is free to rotate on

the idler hub.
5. Install thrust plate (10) to idler hub (9). Ensure that

the thrust plate is correctly positioned onto the
idler hub.
6. Install idler gear assembly (4) onto the cylinder
block. Align the timing marks on the idler gear and
crankshaft gear (5) as shown in Illustration 137 .
Also align the bolt hole in the idler hub with the
holes in the cylinder block.
7. Install retaining plate (3) and bolts (1) and bolt (2).
Ensure that the retaining plate is correctly
orientated.
8. Tighten bolts (1) and bolt (2) to a torque of 70 N·m
(52 lb ft).
9. Check the end play for idler gear assembly (4).
The end play for the gear assembly is
0.05 to 0.35 mm (0.002 to 0.014 inch).
10. If necessary, install engine oil pump idler gear (6).
Refer to Disassembly and Assembly, “Engine Oil
Pump - Install” for the correct procedure.
11. Calibrate the speed/timing sensor. Refer to
Troubleshooting, “Engine Speed/Timing Sensor -
Calibrate ” for the calibration procedure.


bushing (8) to idler gear (7). Ensure that the
80 UENR4511-01
End By:
a. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install” for
i06543361
Housing (Front) - Remove
Removal Procedure
Start By:
a. If necessary, remove the air compressor. Refer
to Disassembly and Assembly, Air
Compressor - Remove and Install for the
correct procedure.
b. Remove the unit injector hydraulic pump. Refer
to Disassembly and Assembly, “Unit Injector
Hydraulic Pump - Remove” for the correct
procedure.
c. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove” for the
correct procedure.
d. Remove the speed timing sensor. Refer to Illustration 138 g03781615
Disassembly and Assembly, “Speed/Timing
Sensor - Remove and Install” for the correct
procedure.
e. Remove the V-Belt adjuster and the bracket.
Refer to Disassembly and Assembly, “V-Belts -
f. Remove the crankshaft front seal. Refer to
g. Remove the engine oil pan. Refer to
NOTICE
and mandates. Illustration 139 g03781617
1. Remove bolt (1) from bracket (2). Position the

NOTICE bracket away from cover (5).
2. Remove bolts (3) and bolts (4) from front cover (5).
Contaminants may cause rapid wear and shortened Identify the positions of bolts of different length.
component life.
Support the front cover as the bolts are removed.
3. Remove front housing (5) from the cylinder block.
UENR4511-01 81
4. Inspect dowel (6) and dowel (7) for damage. If 3. Install Tooling (A) in Positions (X) of the cylinder
necessary, remove the dowels from the cylinder block.
block.
i06543363
Housing (Front) - Install
Table 32
Required Tools
Guide Studs
A - 2
(1/2 - 13 UNC by 6 inch)
Loctite 598 Black High Per-

B - formance RTV Silicone 1
Gasket Maker
NOTICE
component life.
1. Ensure that all components are free from wear or

is worn or damaged.
2. If necessary, install dowel (6) and dowel (7) to the

cylinder block.
82 UENR4511-01

Front housing tightening sequence
4. Clean the gasket surfaces of the cylinder block and

front housing (5).
5. Apply Tooling (B) to front housing (5) as shown in
Illustration 142 .
6. Position front housing (5) over Tooling (A) and
install the front housing to the cylinder block.
Ensure Tooling (B) is not damaged as the front
housing is installed.
7. Install bolts (3) and bolts (4) from front cover (5).
Identify the positions of bolts of different length.
Support the front cover as the bolts are install.
8. Tighten bolts (3) and bolts (4) for front housing (5)
to a torque of 28 N·m (248 lb in) in the tightening
sequence shown in Illustration 143 .
9. Position bracket (2) onto cover (5).Install bolt (1) to
the bracket. Tighten the bolts to a torque of
55 N·m (41 lb ft).
UENR4511-01 83
End By:
a. Install the unit injector hydraulic pump. Refer
to Disassembly and Assembly, “Unit Injector
Hydraulic Pump - Install” for the correct
procedure.
b. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install” for the correct
procedure.
c. Install the speed timing sensor. Refer to
Disassembly and Assembly, “Speed/Timing
Sensor - Remove and Install” for the correct
procedure.
d. Install the crankshaft front seal. Refer to
e. Install the engine oil pan. Refer to Disassembly
f. Install the V-Belt adjuster and the bracket. Refer
to Disassembly and Assembly, “V-Belts -
g. If necessary, install the air compressor. Refer
to Disassembly and AssemblyAir Compressor
- Remove and Install for the correct procedure.
i05986446
1. Loosen hose clamp (4) and disconnect hose
Crankcase Breather - Remove assembly (5) from crankcase breather (1).
2. Remove bolt (1) from crankcase breather (1).
and Install Remove the breather from cylinder block cover
(7).
Removal Procedure
4. Remove sealing washer (3) (not shown) from bolt
NOTICE (1).
tained during performance of inspection, mainte- 5. If necessary, remove the nut and bolt (8) from clip
nance, testing, adjusting and repair of the product. (9). Remove hose assembly (5) from the bracket.
ers before opening any compartment or disassem- Installation Procedure
Dispose of all fluids according to local regulations NOTICE
and mandates. Keep all parts clean from contaminants.
component life.
NOTICE
1. Ensure that all components of the crankcase
Contaminants may cause rapid wear and shortened breather are free from wear or damage.
component life.
84 UENR4511-01
10. Tighten the nut and bolt (8) to a torque of 28 N·m

(248 lb in). Ensure that clip (9) is not strained as
the nut and bolt is tightened.
i05986481
Cylinder Block Cover -

Remove and Install
Removal Procedure
Start By:
a. Remove the electronic control module. Refer to
Disassembly and Assembly, “Electronic
Control Module - Remove and Install” for the
correct procedure.
NOTICE
Illustration 145 g03758497 and mandates.
2. Inspect and clean crankcase breather (1). Refer to

Operation and Maintenance Manual, “Engine NOTICE
Crankcase Breather - Clean” for the correct Keep all parts clean from contaminants.
procedure. Contaminants may cause rapid wear and shortened
3. If necessary, position hose assembly (5) and clip component life.
(9) onto the bracket. Ensure that the hose
assembly and the clip are correctly positioned onto
the bracket.
4. Install the nut and bolt (8) to clip (9). Tighten the
nut and bolt hand tight.
5. Install a new O-ring seal (6) (not shown) onto
crankcase breather (1).
6. Install crankcase breather (1) onto cylinder block
cover (7). Install a new sealing washer (3) (not
shown) onto bolt (2). Loosely install the bolt to the
crankcase breather.
7. Connect hose assembly (5) to crankcase breather
(1).
8. Tighten bolt (2) to a torque of 15 N·m (133 lb in).
(62 lb in).
UENR4511-01 85
1. Loosen hose clamp (4) and disconnect hose 6. Loosen tube nut (11) from connection (10) for tube
assembly (5) from crankcase breather (1). assembly (12).
2. Remove bolt (1) from crankcase breather (1). 7. Disconnect tube nut (13) from elbow connection
Remove the breather from cylinder block cover (14) for tube assembly (12).
(7).
8. Cut cable straps (15) from the clips.
9. Disconnect harness assembly (18) from engine oil
4. Remove sealing washer (3) (not shown) from bolt pressure sensor (17) (not shown). Position the
(1). harness assembly away from cylinder block cover
(7).
5. Remove the nut and bolt (8) from clip (9). Remove
hose assembly (5) from the bracket. 10. Remove bolts (16) from cylinder block cover (7).
Support the cylinder block cover as the bolts are
removed.
11. Remove cylinder block cover (7) from the cylinder
block.
86 UENR4511-01
13. If necessary, follow Step 2.a through Step 2.d in 2. If necessary, follow Step 2.a through Step 2.f in
order to disassemble cylinder block cover (7). order to assemble cylinder block cover (7).
a. Make temporary marks on elbow connection a. Install a new O-ring seal (24) onto connection
(14) and cylinder block cover (7) for (23).
installation purposes.
b. Install connection (23) to cylinder block cover
b. Loosen lock nut (20) on elbow connection (7). Tighten the connection to a torque of
(14). Remove the elbow connection from 30 N·m (266 lb in).
cylinder block cover (7).
c. Install a new O-ring seal (22) to connection
c. Remove O-ring seal (21) from elbow (23). Install engine oil pressure sensor (17) to
connection (14). the connection. Tighten the engine oil
pressure sensor to a torque of 10 N·m
d. Remove engine oil pressure sensor (17) from (89 lb in).
connection (23). Remove O-ring seal (22).
d. Install a new O-ring seal (21) to elbow
e. Remove connection (23) from cylinder block connection (14).
cover (7).
e. Install elbow connection (14) to cylinder block
f. Remove O-ring seal (24) from connection cover (7) and align with temporary makes.
(24). Tighten lock nut (20) hand tight.
Installation Procedure f. Tighten lock nut (20) on elbow connection (14)
to a torque of 65 N·m (48 lb ft). Ensure that
NOTICE the elbow connection does not move as the
locking nut is tightened
component life.
1. Ensure all component for the cylinder block cover

and the breather are free from wear or damage.
Replace any component that is worn or damaged.
UENR4511-01 87
3. Position a new gasket (19) (not shown) onto

cylinder block cover (7). Ensure that the gasket is
correctly orientated.
4. Install cylinder block cover (7) onto the cylinder
block. Loosely connect tube nut (13) to elbow
connection (14) for tube assembly (12).
5. Install bolts (16) to cylinder block cover (7) hand
tight. Support the cylinder block cover as the bolts
are installed.
in a numerical sequence that is shown in
Illustration 151 .
7. Tighten tube nut (11) and tube nut (13) for
connection (10) and elbow connection (14) hand
tight. Ensure that tube assembly (12) is not
strained as the tube nuts are tightened.
8. Tighten tube nut (11) and tube nut (13) to a torque
of 130 N·m (96 lb ft). Use a suitable tooling to hold
elbow connection (14) and connection (10) as the
tube nuts are tightened.
9. Connect harness assembly (18) to engine oil
pressure sensor (17) (not shown).
10. Install new cable straps (15) to the clips.
Note: Ensure that the cable straps meet the Original

Equipment Manufacture (OEM) specification.

Tightening sequence for the cylinder block cover
88 UENR4511-01
End By:
a. Install the electronic control module. Refer to
Disassembly and Assembly, “ Electronic
Control Module - Remove and Install” for the
correct procedure.
i05986458
Valve Mechanism Cover

-Remove and Install
Removal Procedure
NOTICE
and mandates.
NOTICE
Illustration 152 g03770738 Keep all parts clean from contaminants.
11. Position hose assembly (5) and clip (9) onto the Contaminants may cause rapid wear and shortened
bracket. Ensure that the hose assembly and the component life.
clip are correctly positioned onto the bracket.
12. Install the nut and bolt (8) to clip (9). Tighten the
nut and bolt hand tight.
crankcase breather (1).
14. Install crankcase breather (1) onto cylinder block
cover (7). Install a new sealing washer (3) (not
shown) onto bolt (2). Loosely install the bolt to the
crankcase breather.
15. Connect hose assembly (5) to crankcase
breather (1).
16. Connect hose assembly (5) to crankcase
breather (1).
17. Tighten bolt (2) to a torque of 15 N·m (133 lb in).
(62 lb in).
19. Tighten the nut and bolt (8) to a torque of 28 N·m
(248 lb in). Ensure that clip (9) is not strained as
the nut and bolt is tightened.
UENR4511-01 89

Valve mechanism cover tightening sequence
1. Loosen bolts (1) and bolts (2) in the reverse Installation Procedure
numerical tightening sequence. Refer to the Table 33
Illustration 154 . Note the position of different types Required Tools
of bolts for installation purposes.
2. Remove valve mechanism cover (3) from valve
mechanism base (4). Loctite 5940 Black RTV Sili-
A - 1
cone Sealant
3. Remove seal (5) (not shown).
90 UENR4511-01
NOTICE
component life.

Valve mechanism cover tightening sequence
1. Apply Tooling (A) to both sides of seal (5) (not 2. Install seal (5) (not shown) to the recess of valve
shown). mechanism cover (3). Ensure that the seal is
correctly installed to the recess of the valve
mechanism cover.
UENR4511-01 91
3. Position valve mechanism cover (3) onto valve

mechanism base (4). Ensure that the valve
mechanism cover is correctly orientated onto the
valve mechanism base.
4. Install bolts (1) and bolts (2) to valve mechanism
cover (3). Ensure that the different types of bolts
are installed into the correct position.
20 N·m (177 lb in).Tighten the bolts in the
sequence that is shown in Illustration 156 .
i05986459
Valve Mechanism Cover Base -

Remove and Install
Removal Procedure
Start By:
1. Disconnect harness assembly (1) from all
Disassembly and Assembly, “Valve electronic unit injectors (2).
Mechanism Cover - Remove and Install” for the 2. Remove Allen head bolts (3) and bolt (4) from
correct procedure.
harness assembly (1).
NOTICE 3. Disconnect harness assembly (7) from connection
tained during performance of inspection, mainte- (8) on valve mechanism cover base (5).
nance, testing, adjusting and repair of the product. 4. Disconnect harness assembly (9) from
ers before opening any compartment or disassem- atmospheric pressure sensor (10).
bling any component containing fluids. 5. Remove bolts (4), the washers, and the springs
Dispose of all fluids according to local regulations from valve mechanism cover base (5).
and mandates. 6. Remove valve mechanism cover base (5) from the
cylinder head. Ensure that the harness assembly
is not damaged as the valve mechanism cover
NOTICE
Keep all parts clean from contaminants. base is removed.
Contaminants may cause rapid wear and shortened 7. Remove seal (6) (not shown).
component life. 8. If necessary, remove atmospheric pressure sensor
(10) from valve mechanism cover base (5). Refer
to Disassembly and Assembly, “Atmospheric
Pressure Sensor - Remove and Install”for the
correct procedure.
Table 34
Required Tools
Loctite 5940 Black RTV Sili-

A - 1
cone Sealant
92 UENR4511-01
NOTICE
component life.
1. Ensure that valve mechanism cover base and the

cylinder head are clean and free from wear or
damage.

Valve mechanism base tightening sequence
UENR4511-01 93
2. If necessary, install atmospheric pressure sensor End By:

(10) to valve mechanism cover base (5). Refer to
Disassembly and Assembly, “Atmospheric a. Install the valve mechanism cover. Refer to
Pressure Sensor - Remove and Install”for the Mechanism Cover - Remove and Install” for the
correct procedure. correct procedure.
3. Apply Tooling (A) to both sides of seal (6) (not
i05986456
shown).
4. Install seal (5) (not shown) to the recess of valve Rocker Arm and Shaft -
mechanism base (5). Ensure that the seal is Remove
correctly installed to the recess of the valve
mechanism cover.
5. Position valve mechanism base(5) onto the
cylinder head. Ensure that the harness assembly Removal Procedure
is not damaged as the valve mechanism cover Start By:
base is installed.
6. Install the springs, the washers, and bolts (4) to Disassembly and Assembly, “Valve
valve mechanism cover base (5). Hand tighten the Mechanism Cover - Remove and Install” for the
bolts in a numerical sequence that is shown in correct procedure.
Illustration 159 .
NOTICE
7. Tighten bolts (4) to a torque of 28 N·m (248 lb in). Keep all parts clean from contaminants.
Tighten the bolts in a numerical sequence that is Contaminants may cause rapid wear and shortened
shown in Illustration 159 . component life.
8. Connect harness assembly (1) to all electronic unit
injectors (2). 1. Place identification marks on each of the rocker
9. Install new Allen head bolts (3) and a new bolt (4) arms in order to identify the correct location for
to harness assembly (1). installation.
10. Tighten Allen head bolts (3) to a torque of 28 N·m

(248 lb in).
Tighten bolt (4) to a torque of 12 N·m (106 lb in).
Note: Ensure that the clips for the harness assembly
are not strained as the Allen head bolts and the bolt
are tightened.
11. Connect harness assembly (7) to connection (8)

on valve mechanism cover base (5).
12. Connect harness assembly (9) to atmospheric
pressure sensor (10).
2. Loosen all nuts (4) on the rocker arm. Loosen all

adjustment screws (2). Ensure that all adjusters
are fully unscrewed.
94 UENR4511-01
3. Remove bolts (1) and rocker shaft assembly (6).

Remove the rocker shaft assembly from the
cylinder head.
4. Make temporary marks on push rods (5). Remove
the push rods from the engine.
5. Make temporary marks on valve bridges (2).
Remove the valve bridges from the valves.
i05986454
Rocker Arm - Disassemble
Start By:
a. Remove the rocker arm and shaft. Refer to
Disassembly and Assembly, “Rocker Arm and
Shaft - Remove” for the correct procedure.
NOTICE
component life.
Note: Place an identification mark on each of the

components of the rocker shaft for installation
purposes.
UENR4511-01 95
5. If necessary, remove plugs (6) from rocker shaft

(1).
parts propelled by a released spring force. i05986453
Make sure to wear all necessary protective Rocker Arm - Assemble

equipment.
Follow the recommended procedure and use all Assembly Procedure
1. Remove stand (10), inlet rocker arm (9), spring (8),

and exhaust rocker arm (7) from rocker shaft (1). NOTICE
2. If necessary, remove nut (1) from adjuster (3).
Remove the adjuster from exhaust rocker arm (7). Contaminants may cause rapid wear and shortened
component life.
3. If necessary, remove nut (2) from adjuster (4).
Remove the adjuster from inlet rocker arm (9).
1. Lubricate all components of the rocker arm shaft
4. Repeat Step 1 through Step 3 in order to remove with clean engine oil.
the remaining components from the rocker shaft.
96 UENR4511-01
End By:
a. Install the rocker arm and shaft. Refer to
Improper assembly of parts that are spring Disassembly and Assembly, “Rocker Arm and
loaded can cause bodily injury. Shaft - Install” for the correct procedure.
assembly procedure and wear protective i05986455
equipment.
Rocker Arm and Shaft - Install
2. If necessary, use a suitable tool to install plugs (6)
to rocker shaft (1). Installation Procedure
3. If necessary, install adjuster (3) to exhaust rocker
arm (7). Install nut (1) to the adjuster.
4. If necessary, install adjuster (4) to inlet rocker arm NOTICE
(9). Install nut (2) to the adjuster.
5. Install exhaust rocker arm (7), spring (8), inlet Contaminants may cause rapid wear and shortened
component life.
rocker arm (9), and stand (10) to rocker shaft (1).
6. Repeat Step 1 through Step 5 in order to install the
remaining components to the rocker shaft.
UENR4511-01 97

Rocker shaft bolts tightening sequence
1. Clean push rods (5). Inspect the push rods for Note: Ensure that the push rods are installed in the
wear and damage. Replace any push rods that are original location. Ensure that the ball end of each
worn or damaged. push rod is correctly seated in the valve lifters.
2. Lubricate to both ends of push rods (5). Install the
push rods into the engine with clean engine oil.
98 UENR4511-01
3. Clean valve bridges (2). Inspect the valve bridges Start By:
for wear and damage. Replace any valve bridges
that are worn or damaged. a. Remove the air cleaner and the bracket. Refer
to Disassembly and Assembly, “Air Cleaner -
NOTICE
Failure to ensure that ALL valve bridges are correctly b. Remove the fan drive. Refer to Disassembly
seated onto the valve stems will cause interference and Assembly, “Fan Drive - Remove” for the
between the pistons and the valves, resulting in dam- correct procedure.
age to the engine.
c. Remove the rocker arm and shaft. Refer to
4. Install valve bridges (2) onto the valves. Shaft - Remove” for the correct procedure.
Note: Install used valve bridges in the original d. Remove the valve mechanism cover base.
location and in the original orientation. Ensure that Refer to Disassembly and Assembly, “Valve
the valve bridges are correctly seated on the valves. Mechanism Cover Base - Remove and Install”
New valve bridges may be installed in either for the correct procedure.
orientation.
NOTICE
5. Position rocker shaft (4) on the cylinder head. Care must be taken to ensure that fluids are con-
Install bolts (1) hand tight. nance, testing, adjusting and repair of the product.
6. Tighten bolts (1) in the sequence shown. Tighten Be prepared to collect the fluid with suitable contain-
bolts (1) to a torque of 100 N·m (74 lb ft). ers before opening any compartment or disassem-
7. Lubricate each of the bottom faces of the rocker
arms with clean engine oil.
and mandates.
8. Position rocker arm adjustment screws (3) into
each push rods (5).
NOTICE
Note: Ensure that the adjusting are correctly seated Keep all parts clean from contaminants.
in ends of the push rods.
9. Adjust the valve lash of the rocker arms. Tighten component life.
nuts (4) to a torque of 30 N·m (266 lb in) after the
engine valve lash has been adjusted. Refer to 1. Turn the fuel supply to the OFF position.
Testing and Adjusting, “Engine Valve Lash -
2. If necessary, remove the coolant out tube
Inspect/Adjust” for the correct procedure.
assembly for the thermostats housing and the
End By: radiator. Refer to the Original Equipment
Manufacture (OEM) for the correct procedure.
a. Install the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve 3. If necessary, remove the tube assembly from the
correct procedure. turbocharger out connection and the air to air
charge cooler. Refer to the OEM for the correct
i05986349
procedure.
4. If necessary, remove the tube assembly from the
Cylinder Head - Remove inlet manifold connection and the air to air charge
cooler. Refer to the OEM for the correct
procedure.
Removal Procedure 5. If necessary, remove the OEM exhaust tube
Table 35 assembly from the exhaust elbow. Refer to the
OEM for the correct procedure.
Required Tools
6. If necessary, remove the radiator support brackets.
Refer to the OEM for the correct procedure.
A T401089 Link Bracket 2
UENR4511-01 99

System Coolant (ELC) - Change” for the correct
procedure.
17. Disconnect tube nut (16) and tube nut (23).

Remove the hose assembly from the turbocharger
(17) and the connection on the engine oil cooler.
Illustration 165 g03773232 18. Remove O-ring seal (17) (not shown) and O-ring
8. Remove bolt (1) and spacer (2) from the alternator
19. Remove bolts (20) and bolts (21). Remove tube
adjusting link.
assemble (23).
9. Remove bolts (9) and remove bracket (10).
20. Remove gasket (19) (not shown) and gasket (22)
Support the bracket as the bolts are removed.
(not shown).
10. Disconnect hose assembly (11) from the
connection on the cylinder head.
Ensure that the hose clamp is sufficiently loosened
11. Disconnect the hose assembly from connection in order to allow the hose assembly to be
(15) on the cylinder head. disconnected from the thermostat housing.
12. Disconnect harness assembly (3) from coolant
temperature sensor (4) (not shown).
13. Disconnect harness assembly (5) from inlet
manifold pressure sensor (6) (not shown).
manifold temperature sensor (8) (not shown).
15. Disconnect harness assembly (12) from rail
16. Make temporary marks for all cable strap (14) on
the harness assemble for installation purposes.
Cut the cable straps and position the harness
assemble away from the cylinder head.
100 UENR4511-01

Sequence for tightening the bolts for the cylinder head
UENR4511-01 101

22. Gradually loosen bolts (28) and bolts (29) in the

reverse numerical sequence. Refer to the
Illustration 168 and 169 .
23. Remove bolts (28) and bolts (29) from the
cylinder head (30).
102 UENR4511-01
28. Remove gasket (32) and O-ring seal (33).
i05986340
Cylinder Head - Install
Table 36
Required Tools
A T401089 Link Bracket 2

Guide Studs
B - 2
M16 x 2.00 by 200 mm
C CV60889 Anti-Seize Compound 1

NOTICE
component life.
24. Attach Tooling (A) and a suitable lifting device

onto cylinder head (30). The weight of the cylinder
head is approximately 181 kg (400 lb).
25. Use the suitable lifting device to remove cylinder
head (30) from cylinder block (35).
26. Place cylinder head (30) on a suitable surface.
Note: Use caution in order not to damage the tips

of the injectors.
27. Note the position of dowel (31) and dowel (34) in

cylinder block (35).
UENR4511-01 103

1. Inspect dowel (31) and dowel (34) for damage. If
necessary, replace the dowels in the cylinder
block.
2. Install Tooling (B) to cylinder block (35).
3. Align a new gasket (32) with dowel (31), dowel
(34), and Tooling (B).
4. Install the new O-ring seal (33) to the recess in
cylinder block (35). Ensure that the O-ring is
correctly seated into the recess.
5. Attach Tooling (A) and a suitable lifting device onto
cylinder head (28). The weight of the cylinder head
is approximately 181 kg (400 lb).
6. Use the suitable lifting device to lift cylinder head
(30).
7. Use Tooling (B) to align cylinder head (30) with
cylinder block (35). Install the cylinder head to the
cylinder block. Ensure that the hose assembly
for the thermostat housing is correctly located
Illustration 173 g03773234 onto the water pump connection.
8. Apply Tooling (C) to the threads of bolts (28) and
bolts (29).
9. Install bolts (28) and bolts (29) to cylinder head
(30).
10. Remove Tooling (B) from the cylinder block (35).
Install remaining bolts (28) to cylinder head (29).
104 UENR4511-01

UENR4511-01 105

11. Follow Step 11.a through Step 11.g to tighten

bolts (28) according to the following procedure
a. Tighten bolts (28) in a numerical sequence

that is shown in Illustration 176 to a torque of
130 N·m (96 lb ft).
b. Tighten bolts (28) in a numerical sequence

130 N·m (96 lb ft).
c. Place a mark on bolts (28) and cylinder head

(27). Turn the bolts through an additional 90
degrees in the numerical Sequence shown in
Illustration 176 .
d. Fully loosen bolts (28).
e. Tighten bolts (28) in a numerical sequence

130 N·m (96 lb ft).
f. Tighten bolts (28) in a numerical sequence
13. Tighten hose clamp (26) for hose assembly (27)
130 N·m (96 lb ft).
g. Place a mark on bolt (28) and cylinder head 14. Position a new gasket (19) (not shown) and a
(30). Turn the bolts through an additional 90 new gasket (22) (not shown) onto tube assemble
degrees in the numerical Sequence shown in (23).
Illustration 176 .
15. Position tube assembly (23) onto turbocharger
12. Tighten bolts (29) in a numerical sequence that is (18) and the cylinder block. Install bolts (20) and
shown in Illustration 177 to a torque of 28 N·m bolts (21) hand tight.
(248 lb in).
28 N·m (248 lb in).
106 UENR4511-01
17. Install a new O-ring seal (17) (not shown) and a 27. Connect harness assembly (12) to rail pressure
new O-ring seal (25) (not shown) to the sensor (13) (not shown).
connections on turbocharger (18) the engine oil
28. Install all new cable strap (14) onto the harness
cooler. Ensure that the O-ring seals are correctly
assemble. Ensure that the new cable straps are
installed into the connections.
installed in the original position.
18. Install the hose assembly onto the turbocharger
(17) and the connection on the engine oil cooler. Note: Ensure that the cable straps meet Original
Tighten tube nut (16) and tube nut (23) to a torque Equipment Manufacture (OEM) specification.
of 45 N·m (33 lb ft). Ensure that the hose 29. If necessary, install the coolant out tube assembly
assembly is not strained or come into contact with for the thermostats housing and the radiator. Refer
other engine components to the OEM for the correct procedure.
30. If necessary, install the tube assembly to the
turbocharger out connection and the air to air
charge cooler. Refer to the OEM for the correct
procedure.
31. If necessary, install the tube assembly to the inlet
manifold connection and the air to air charge
cooler. Refer to the OEM for the correct
procedure.
32. If necessary, install the OEM exhaust tube
assembly to the exhaust elbow. Refer to the OEM
for the correct procedure.
33. If necessary, install the radiator support brackets.
34. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant (ELC) - Change” and Operation
and Maintenance Manual, “Capacities (Refill)”.
Illustration 179 g03773232 35. Turn the fuel supply to the ON position.
19. Position bracket (10) onto cylinder head. Install

bolts (9) hand tight. Support the bracket as the
bolts are installed .
20. Loosely install bolt (1) and spacer (2) to the
alternator adjusting link.
22. Connect hose assembly (11) to the connection on
the cylinder head. Tighten the tube nut for the
hose assembly to a torque of 30 N·m (266 lb in).
23. Connect the hose assembly to connection (15) on
the cylinder head. Tighten the tube nut for the
hose assembly to a torque of 30 N·m (266 lb in).
24. Connect harness assembly (3) to coolant
25. Connect harness assembly (5) to inlet manifold
UENR4511-01 107
End By:
a. Install the valve mechanism cover base. Refer
to Disassembly and Assembly, “Valve
Mechanism Cover Base - Remove and Install”
b. Install the rocker arm and shaft. Refer to
Shaft - Install” for the correct procedure.
c. Install the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Install” for the correct
procedure.
d. Install the air cleaner and the bracket. Refer to
Disassembly and Assembly, “Air Cleaner -
i05986452
Lifter Group - Remove and

Install
Typical example
Removal Procedure 1. Use a suitable tool to remove valve lifter (2) from
the cylinder block.
Start By:
Note: Make a temporary mark on each lifter in order
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head - to identify the lifter of installation purposes.
2. Remove guide spring (1) from valve lifter (2).
3. Repeat Step 1 through Step 2 for the remaining
lifters.
parts propelled by a released spring force. Installation Procedure
equipment.
Follow the recommended procedure and use all Personal injury can result from being struck by
recommended tooling to release the spring force. parts propelled by a released spring force.
equipment.
NOTICE
Keep all parts clean from contaminants. Follow the recommended procedure and use all
component life.
NOTICE
component life.
1. Ensure that all components are clean and free

from wear or damage. Replace any components
that are worn or damaged.
108 UENR4511-01
Start By:
a. Remove the rocker arm and the shaft. Refer to
Shaft - Remove” for the correct procedure.
b. Remove the lifter from the cylinder block. Refer
to Disassembly and Assembly, “Lifter Group-
c. Remove the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove and
NOTICE
component life.

Typical example
2. Install new guide spring (1) to valve lifter (2).

3. Lubricate the roller pin with clean engine oil prior to
installation.
Note: Ensure that rollers are free to rotate.
4. Install valve lifter (2) to the cylinder block. Ensure

that used lifters are installed in the correct
location.
5. Repeat Step 2 through Step 4 in order to install the
remaining lifters.
End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i05986442
Camshaft - Remove
Removal Procedure
Table 37
Required Tools
A CH11148 Engine Turning Tool 1
UENR4511-01 109
1. Use Tooling (A) in order to rotate the crankshaft so

that number one piston is at top dead center. Refer
to System Operation, Testing and Adjusting,
“Finding Top Center Position for No.1 Piston” for
2. Ensure that the timing marks on camshaft gear (2)
and idler gear (1) are aligned.
3. Remove bolts (3) from thrust plate (4).
4. Remove thrust plate (4) from camshaft (5).
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
5. Use a suitable tool to remove camshaft (5) from

the cylinder block. Ensure that camshaft bearings
(6) are not damaged as the camshaft is removed.
110 UENR4511-01
6. If necessary, remove camshaft gear (2) from the

camshaft. Refer to Disassembly and Assembly,
“Camshaft Gear - Remove and Install” for the
correct procedure.
i05986441
Camshaft - Install
Table 38
Required Tools
21825617 Dial Gauge 1

B
- Magnetic Base and Stand 1
NOTICE
component life.
NOTICE
UENR4511-01 111
Do not damage the lobes or the bearings when the End By:
camshaft is removed or installed.
a. Install the front cover. Refer to Disassembly
and Assembly, “Front Cover - Remove and
NOTICE Install” for the correct procedure.
When installing the camshaft, make sure the number
one cylinder is at top center of the compression b. Install the lifter to the cylinder block. Refer to
stroke with the timing bolt installed in the flywheel. Disassembly and Assembly, “Lifter Group-
The camshaft timing is very important. The timing Remove and Install” for the correct procedure.
mark on the camshaft drive gear must line up with the c. Install the rocker arm and the shaft. Refer to
timing mark on the idler gear. Refer to the Specifica- Disassembly and Assembly, “Rocker Arm and
tions Manual for more information. Shaft - Install” for the correct procedure.
d. Calibrate the speed/timing sensor. Refer to
Note: During the installation of the camshaft, rotate Troubleshooting, “Engine Speed/Timing
the camshaft in both directions in order to prevent Sensor - Calibrate” for the correct procedure.
binding in the camshaft bearing bores.
i05986445
1. If necessary, install camshaft gear (2) to the
camshaft. Refer to Disassembly and Assembly,
“Camshaft Gear - Remove and Install” for the
Camshaft Gear - Remove and
correct procedure. Install
2. If necessary, use Tooling (A) in order to rotate the
crankshaft so that number one piston is at top
dead center. Refer to Testing and Adjusting, Removal Procedure
“Finding Top Center Position for No 1 Piston” for
the correct procedure. Start By:
3. Lubricate camshaft (7) lobes and camshaft bearing a. Remove the camshaft. Refer to Disassembly
and Assembly, “Camshaft - Remove” for the
journals with a clean lubricating engine oil. Apply
correct procedure.
clean lubricating engine oil onto camshaft
bearings (6). NOTICE
4. Carefully install camshaft (7) to the cylinder block. Keep all parts clean from contaminants.
Ensure that camshaft bearings (6) are not Contaminants may cause rapid wear and shortened
damaged as the camshaft is installed. component life.
5. Align the timing marks on camshaft gear (2) and
idler gear (1) are aligned.
6. Install thrust plate (4) to camshaft (5).
7. Install bolts (3) to thrust plate (4). Tighten the bolts
8. Use Tooling (B) to check that the maximum
permissible end play for a worn camshaft is
0.46 mm (0.018 inch). The maximum permissible
end play for a new camshaft is 0.13 ± 0.08 mm
(0.005 ± 0.003 inch).
112 UENR4511-01
1. Wrap camshaft (2) with a protective covering, in

order to prevent damage to the camshaft the lobes
or the bearings surfaces.
2. Use a suitable press to remove camshaft (2) from
camshaft gear (1).
3. If necessary, remove key (3) from camshaft (2).
Table 39
Required Tools
A - Hot Plate 1
NOTICE
component life.
1. Ensure that the camshaft gear, the camshaft, and

the key are clean and free from wear and damage.
2. If necessary, install key (3) to camshaft (2).

3. Position camshaft (2) into the vertical position.
Ensure that the camshaft is correctly supported.
NOTICE 4. Use Tooling (A) to raise the temperature of the

Do not allow the camshaft to fall to the floor when camshaft gear up to a temperature of 177 °C
pressing it from the drive gear. Also make sure that (350 °F).
the camshaft lobes do not catch on the press plates.
Note: The temperature of the camshaft gear must
not exceed 177 °C (350 °F) during installation.
UENR4511-01 113
5. Align key (3) with the keyway (4) in camshaft gear

(1). Install the camshaft gear onto the camshaft.
Ensure that the camshaft gear is correctly seated
onto the camshaft.
End By:
a. Install the camshaft. Refer to Disassembly and
procedure.
i05986489
Camshaft Bearings - Remove

Removal Procedure 1. Use Tooling (A) to remove the camshaft bearings

Table 40 from the cylinder block.
Required Tools
i05986491
A T401074 Camshaft Bearing Tool Group 1

Camshaft Bearings - Install
Start By:
a. Remove the camshaft. Refer to Disassembly Installation Procedure
and Assembly, “Camshaft - Remove” for the Table 41
correct procedure.
Required Tools
b. Remove the flywheel housing. Refer to Tool Part Number Part Description Qty
Disassembly and Assembly, “Flywheel
Housing- Remove and Install” for the correct A T401074 Camshaft Bearing Tool Group 1
procedure.
Note: Note the oil hole orientation in each camshaft NOTICE
bearing prior to removal for assembly purposes. Keep all parts clean from contaminants.
NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

component life. NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine
NOTICE damage.
and mandates.
114 UENR4511-01
2. Use Tooling (A) to install camshaft bearing (2),

camshaft bearing (3), and camshaft bearing (4)
that are behind the front camshaft bearing. Install
the camshaft bearings to the correct depths. Refer
to Illustration 190 and refer to Step 1. Orientate the
camshaft bearings so that oil holes (5) in the
camshaft bearings are located at the tops of the
bores in the cylinder block and camshaft bearing
joints (6) are positioned as shown in Illustration
191 .
3. Use Tooling (A) to install front camshaft bearing

(4). Carefully align oil hole (8) in the oil gallery in
the cylinder block. Orientate joint (7) as shown in
Illustration 192 .
1. Refer to Illustration 190 for the locations of the

camshaft bearings.
(1) Installation Dimension (A) for camshaft bearing

(1) . . . . . . . . . . . 816.5 ± 0.8 mm ((32.15 ± 0.03 inch))
(2) Installation Dimension (B) for camshaft bearing

(2) . . . . . . . . . . . 536.5 ± 0.8 mm ((21.12 ± 0.03 inch))
(3) Installation Dimension (C) for camshaft bearing

(3) . . . . . . . . . . . 294.5 ± 0.8 mm ((11.59 ± 0.03 inch))
(4) Installation Dimension (D) for camshaft bearing

(4) . . . . . . . . . . 0.50 ± 0.25 mm ((0.020 ± 0.010 inch))
UENR4511-01 115
End By:
a. Install the flywheel housing. Refer to
Housing - Remove and Install” for the correct
procedure.
b. Install the camshaft. Refer to Disassembly and
procedure.
i05986417
Engine Oil Pan - Remove and

Install
Removal Procedure

Hot oil and components can cause personal
injury. 1. Open drain valve (4) and drain the engine oil into a
Do not allow hot oil or components to contact suitable container for storage or disposal. Refer to
skin. Operation and Maintenance Manual, “Engine Oil -
Change” for the correct procedure.
NOTICE 2. Support the assembly of engine oil pan (1).

Care must be taken to ensure that fluids are con- 3. Remove bolts (2) and remove assembly of engine
nance, testing, adjusting and repair of the product. oil pan (1).
Be prepared to collect the fluid with suitable contain- 4. Remove gasket (3).
and mandates.
NOTICE
component life.

order to disassemble the assembly of engine oil
pan (1).
116 UENR4511-01
a. Make temporary marks on tube assembly (6)

for assembly purposes.
b. Loosen nut (5) and remove tube assembly (6)

from engine oil pan (1).
c. Make temporary marks on drain valve (4) for

assembly purposes. Loosen locking nut (8)
and remove the drain valve from engine oil
pan (1).
d. Remove O-ring seal (7) (not shown) from drain

valve (4)
Table 42
Required Tools
Loctite 598 Black High Per-

- - Illustration 195 g03779397
A formance RTV Silicone
Gasket Maker
order to assemble the assembly of engine oil pan
NOTICE (1).
a. Install a new O-ring seal (7) (not shown) to
drain valve (4). Install the drain valve to engine
component life.
oil pan (1) and align with temporary marks.
1. Ensure that all components of the engine oil pan b. Tighten locking nut (8) to a torque of 40 N·m
are free from wear or damage. If necessary, (30 lb ft). Use a suitable tool to hold the drain
replace any component that is worn or damaged. valve as the locking nut is tightened. Ensure
that the drain valve is still aligned to the
temporary marks.
c. Install tube assembly (6) to engine oil pan (1).

Align tube assembly with temporary marks.
d. Tighten nut (5) to a torque of 28 N·m

(248 lb in). Use a suitable tool to hold the tube
assembly as the nut is tightened. Ensure that
the tube assembly is still aligned to the
temporary marks.
UENR4511-01 117
3. Clean the gasket surface of engine oil pan (1) and 7. Tighten the remaining bolts (2) starting in Position
the cylinder block. Apply Tooling (A) to four areas (Z) to a torque of 31 N·m (274 lb in) in a
on the sealing surface of the engine oil pan. The counterclockwise sequence.
areas are Marked Location (Y).
4. Place a new gasket (3) onto engine oil pan (1).
5. Install assembly of engine oil pan (1). Install bolts
(2) to the assembly of engine oil pan hand tight.
6. Tighten four bolts (2) in Position (X) to a torque of
31 N·m (274 lb in).
118 UENR4511-01
8. Fill the engine with engine oil to the correct level

and if necessary, replace the engine oil filter. Refer
to Operation and Maintenance Manual, “Engine
Oil - Change” and Operation and Maintenance
Manual, “Capacities (Refill)” for the correct
procedure.
i05986450
Cylinder Liner - Remove
Removal Procedure
Table 43
Required Tools
A GE50001 Cylinder Pack Puller 1

Start By:
a. Remove the pistons and connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Remove” for the
correct procedure.
NOTICE
and mandates.
NOTICE
component life.
1. Use Tooling (A) to remove cylinder liners (1) from

the cylinder block.
2. Remove O-ring seal (2) from cylinder liners (1).
UENR4511-01 119
3. If necessary, repeat Step 1 through Step 2 in order

to remove the remaining cylinder lines.
i05986449
Cylinder Liner - Install
Table 44
Required Tools
B GE50000 Cylinder Liner Installer 1
Delphi Lockheed Rubber

C - 1
Grease
NOTICE
Keep all parts clean from contaminants. Illustration 200 g03774280

component life.
1. Check the cylinder liner projection. Refer to Testing

and Adjusting, “Cylinder Liner Projection - Inspect”
2. Apply Tooling (C) to O-ring seal (2). Install the O-

ring seal in the machined groove on cylinder liner
(1).
3. Lubricate the lower portion of cylinder liner (1) with
clean engine oil. Ensure that the corresponding
crankshaft throw is at the bottom center. Use
Tooling (B) to install cylinder liner (1).
4. If necessary, repeat Step 2 through Step 3 in order
to install the remaining cylinder lines.
120 UENR4511-01
End By: 2. Remove bolt (1) and remove piston cooling jet (2)
from the cylinder block.
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and Installation Procedure
Connecting Rods - Install” for the correct
procedure. Table 46
Required Tools
i05986308
Piston Cooling Jets - Remove A CH11148 Engine Turning Tool 1
and Install
NOTICE
Removal Procedure Contaminants may cause rapid wear and shortened
Table 45 component life.
Required Tools
Start By:
a. Remove the engine oil pan. Refer to
NOTICE
component life.
1. Use Tooling (A) to rotate the crankshaft in order to

gain access to piston cooling jet (2).
Note: Engine damage may occur if the piston cooling

jet is not installed correctly. Install the piston cooling
jet by hand.
2. Position piston cooling jet (2) in the cylinder block.

Ensure that the piston cooling jet is flush with the
cylinder block. Install bolt (1). Tighten the bolt to a
1. Use Tooling (A) to rotate the crankshaft in order to

gain access to piston cooling jet (2).
UENR4511-01 121
End By:
i05986482
Pistons and Connecting Rods

- Remove
Removal Procedure
Table 47
Required Tools

Start By:
a. Remove the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
b. Remove the engine oil pump. Refer to
c. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling
Jets - Remove and Install” for the correct
procedure.
NOTICE
component life.
1. Use Tooling (A) to turn the crankshaft until two of

the connecting rod caps are at the bottom center.
2. Inspect connecting rod (3) and connecting rod cap
(1) for the correct identification mark. Connecting
rod (3) and connecting rod cap (1) should have an
etched number on the side that is toward the
camshaft. The number should match the cylinder
number. if necessary mark connecting rod (3) and
connecting rod cap (1).
122 UENR4511-01
Note: This engine has fractured connecting rods.

Fractured connecting rods must be handled with
care. Use a soft faced hammer in order to tap the
connecting rod cap, if necessary.
3. Loosen connecting rod cap bolts (2). Remove

connecting rod cap bolts (2).
4. Remove connecting rod cap (1) from connecting
(3).
5. Remove the lower half of connecting rod bearing
(5) from connecting rod cap (1).
6. Push the piston and connecting rod assembly (3)
away from the crankshaft. Remove the upper half
of connecting rod bearing (4) from connecting rod
(3).
7. Remove the piston and connecting rod assembly
(3) from the cylinder liner.
i05986434

- Disassemble
Table 48
Required Tools
A - Piston Ring Expander 1
B - Retaining Ring Pliers 1
Start By:
a. Remove the pistons and connecting rods.
Refer to Disassembly and Assembly, “Pistons
and Connecting Rods - Remove” for the
correct procedure.
NOTICE
Note: This engine has fractured connecting rods.
Contaminants may cause rapid wear and shortened Fractured connecting rods must be handled with
component life. care. When possible, the connecting rod assembly
should be kept bolted together in order to protect the
fractured surface when the connecting rod is out of
the engine.
1. Use Tooling (B) in order to remove circlips (3) from

piston skirt (2).
2. Remove piston pin (4) and separate piston skirt (2)
and piston crown (6) from connecting rod (1).
3. Inspect bearings (7) in the piston crown (6).
UENR4511-01 123
4. Use Tooling (A) to remove piston rings (5).

NOTICE
Verify correct assembly of the pistons and the con-
necting rods. Ensure that the etched numbers on the
rod and the rod cap are in the correct positions. The
etched number on the rod and the rod cap corre-
spond to the cylinder in which it should be installed.
NOTICE
The connecting rod must be heated for the installa-
tion of the piston pin bearing. Do not use a torch.
5. Raise the temperature of connecting rod (1) along

Length (X). The maximum distance of Length (X)
is 83.0 mm (3.27 inch). Length (X) should raise
the temperature from 175° to 260°C
(347 to 500°F) in order to assemble bearing.
6. Remove old bearing (8) and install a new bearing Illustration 209 g03781750
(8) at the same time.

7. The bearing split line must be within 5 degrees of
one of the locations that are indicated by the
arrows.
i05986433

- Assemble
Assembly Procedure
Table 49
Required Tools
A - Piston Ring Expander 1
B - Retaining Ring Pliers 1

NOTICE Note: This engine has fractured connecting rods.

Keep all parts clean from contaminants. Fractured connecting rods must be handled with
care. Hold the connecting rod in a soft jawed vise.
Contaminants may cause rapid wear and shortened Then assemble the piston pin to the connecting rod,
component life. the piston skirt, and the piston crown.
124 UENR4511-01
1. Check the clearance between the ends of piston

NOTICE
rings (5). Refer to Specifications, “Piston and The joint between the connecting rod and the con-
Rings” for the correct information. necting rod cap is produced by fracturing. The con-
necting rod assembly must be handled with care in
2. Use Tooling (A) to install the oil control piston ring. order to avoid damage to the mating surfaces. The
The ends of the spring should be rotated 180 connecting rod assembly must be replaced if any
degrees from the ring end gap. damage occurs to the mating surfaces. New connect-
ing rod assemblies come with the connecting rod
3. Use Tooling (A) to install the intermediate piston caps bolted on the connecting rod.
ring with the side marked “UP-2” toward the top of
the piston. Use only a soft jawed vise to hold the connecting rod
assembly when removing the connecting rod cap
4. Use Tooling (A) to install the top piston ring with bolts. Use only a soft faced hammer to tap the con-
the side marked “UP-1” toward the top of the necting rod cap when separating the connecting rod
piston. cap from the connecting rod.
5. Inspect bearings (7) in piston crown (6). The piston Failure to use a soft jawed vise and a soft faced ham-
crown must be replaced if the piston crown is worn mer may result in damage to the connecting rod
or damaged. assembly.
6. Position piston skirt (2) and piston crown (6) on

1. Apply clean engine oil to the pistons, the piston
connecting rod (1). Apply clean engine oil to pin
rings, and the cylinder bore.
(4) and install pin (4). Use Tooling (B) to install
circlips (3). Ensure that circlips (3) are correctly in
the grooves of piston skirt (2).
End By:
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install” for the correct
procedure.
i05986473

- Install
Typical Example
Table 50 2. Place Tooling (B) over both fractured ends of the
Required Tools connecting rod.
Part Description Qty 3. Position the piston rings so that the end gaps are
Tool Part Number
located 120 degrees from each other. Use Tooling
A CH11148 Engine Turning Tool 1 (C) to compress the piston rings.
B - Plastic Cap 2
C T401075 Piston Ring Compressor 1
NOTICE
component life.
UENR4511-01 125
9. Apply clean engine oil to the surface of the lower

half of connecting rod bearing (5). Install
connecting rod cap (1) on connecting rod (3).
Ensure that the number on connecting rod cap (1)
matches the number on connecting rod (3).
Ensure that the numbers are on the same side.
10. Install new connecting rod cap bolts (2). Tighten
connecting rod cap bolts (2) to a torque of 50 N·m
(37 lb ft).
11. Place an index mark on each connecting rod cap
bolt. Tighten each connecting rod cap bolt (2) for
an additional 90 ± 5 degrees.
12. Use Tooling (A) ensure that the installed
connecting rod assembly has tactile side play.
Rotate the crankshaft in order to ensure that there
is no binding.
End By:

a. Install the piston cooling jets. Refer to
Jets - Remove and Install” for the correct
4. Position the crankshaft throw at the bottom center procedure.
position, install the piston and connecting rod
assembly (3) into the cylinder liner. Ensure that the b. Install the engine oil pump. Refer to
correct piston and connecting rod are in the Disassembly and Assembly, “Engine Oil Pump
corresponding cylinder with the identification mark
on the connecting rod on the side that is toward c. Install the cylinder head. Refer to Disassembly
the camshaft. and Assembly, “Cylinder Head - Install” for the
correct procedure.
Note: The forged part number on the connecting rod
must be installed toward the flywheel end of the i05986479
engine.
5. Line up the piston and connecting rod assembly

Connecting Rod Bearings -
(3) with the crankshaft. Use a soft faced hammer Remove
and tap the piston and connecting rod assembly
into the cylinder bore.
6. Before connecting rod (3) comes in contact with Removal Procedure
the crankshaft, remove Tooling (B) and install the
Table 51
upper half of connecting rod bearing (4). Ensure
that the bearing tab engages with the slot in Required Tools
connecting rod (3). Tool Part Number Part Description Qty
7. Apply clean engine oil to the surface of the upper A CH11148 Engine Turning Tool 1
half of connecting rod bearing (4). Use a soft faced
hammer in order to tap the piston and connecting
Start By:
rod assembly further into the cylinder bore while
you guide connecting rod (3) onto the crankshaft. a. Remove the engine oil pump. Refer to
8. Place the lower half of connecting rod bearing (5) - Remove” for the correct procedure.
in corresponding connecting rod cap (1). Ensure
that the bearing tab engages with the groove in NOTICE
connecting rod cap (1). Keep all parts clean from contaminants.
component life.
126 UENR4511-01
Note: Do not damage the fractured faces of the

connecting rod. Place a suitable protective cap on
the ends of the connecting rod in order to prevent
damage to the fractured faces of the connecting rod.
i05986241
Connecting Rod Bearings -

Install
Table 52
Required Tools
1. Use Tooling (A) to turn the crankshaft until the Tool Part Number Part Description Qty
connecting rod bearing caps are accessible.
2. Check connecting rod (3) and connecting rod caps
(1) for identification and for the location. B 21825607 Degree Wheel 1
3. Remove bolts (2). Remove connecting rod cap (1)

from connecting rod (3). Remove the lower half of NOTICE
connecting rod bearing (5) from connecting rod Keep all parts clean from contaminants.
cap (1).
Note: This engine has fractured connecting rods. component life.
Fractured connecting rods must be handled with
care. Use a soft faced hammer in order to tap the
connecting rod cap, if necessary. NOTICE
The joint between the connecting rod and the con-
Note: Do not place the fractured faces of the necting rod cap is produced by fracturing. The con-
connecting rod cap on any surface. The connecting necting rod assembly must be handled with care in
order to avoid damage to the mating surfaces. The
rod cap must be laid flat on the side in order to connecting rod assembly must be replaced if any
prevent damage to the fractured faces of the damage occurs to the mating surfaces. New connect-
connecting rod cap. ing rod assemblies come with the connecting rod
caps bolted on the connecting rod.
4. Push connecting rod (3) away from the crankshaft.
Remove the upper half of connecting rod bearing Use only a soft faced hammer to tap the connecting
(4) from connecting rod (3). rod cap when separating the connecting rod cap from
the connecting rod.
Failure to use a soft faced hammer may result in
damage to the fractured surfaces of the connecting
rod assembly.
1. Use Tooling (A) to turn the crankshaft until the

connecting rod bearing cap is accessible.
UENR4511-01 127
9. Ensure that the installed connecting rod assembly

has tactile side play. Use Tooling (A) to rotate the
crankshaft in order to ensure that the crankshaft
turns freely.
End By:
a. Install the engine oil pump. Refer to
i05986487
Crankshaft Main Bearings -

Remove
(Crankshaft in Position)
Note: Install the connecting rod bearings dry when
clearance checks are performed. Apply clean engine
oil to the connecting rod bearings for final assembly.
Removal Procedure
2. Remove the protective caps from the end of the Table 53
connecting rod and install the upper half of
Required Tools
connecting rod bearing (4). Ensure that the
bearing tab engages with the slot in connecting Tool Part Number Part Description Qty
rod (3).
A 27610319 Bearing Tool 1
3. Pull the piston and connecting rod assembly onto
the crankshaft. Start By:
4. Install the lower half of connecting rod bearing (5)
a. Remove the engine oil pump. Refer to
into connecting rod cap (1). Ensure that the Disassembly and Assembly, “Engine Oil Pump
bearing tab engages with the slot in connecting - Remove” for the correct procedure.
rod cap (1).
NOTICE
Note: Do not place the fractured faces of the This procedure must only be used to remove and in-
connecting rod cap on any surface. The connecting stall the main bearing shells with the crankshaft in po-
rod cap must be laid flat on the side in order to sition. Main bearing shells removal procedure and
prevent damage to the fractured faces of the the installation procedure must be completed for
connecting rod cap. each pair of main bearing shells before the next pair
of main bearing shells are removed.
Note: Ensure that the number on the connecting rod
cap matches the number on the connecting rod.
Make sure that both of the numbers are located on NOTICE
the same side. Keep all parts clean from contaminants.
5. Install connecting rod cap (1) and connecting rod Contaminants may cause rapid wear and shortened
cap bolts (2). component life.
6. Check the bearing clearance. Refer to

Disassembly and Assembly, “Bearing Clearance -
Check” for the correct procedure.
7. Tighten connecting rod cap bolts (2) to a torque of
50 N·m (37 lb ft).
8. Turn the bolts for an additional 90 ± 5 degrees in a
clockwise direction. Use Tooling (B) to achieve the
correct final torque.
128 UENR4511-01
NOTICE
If the crankshaft is turned in the wrong direction, the
tab of the crankshaft main bearing will be pushed be-
tween the crankshaft and the cylinder block. this can
cause damage to either or both the crankshaft and
the cylinder block.
3. Install Tooling (A) in the crankshaft journal.

4. Turn the crankshaft in order to remove the upper
half of the crankshaft main bearing.
Note: The upper main bearing shell has a groove

and two oil holes.
5. Remove thrust washers (3) from number 6 main

bearing in the cylinder block.
i05986480
Crankshaft Main Bearings -

Install
(Crankshaft in Position)
Illustration 215 g03769476 Installation Procedure

Table 54
Required Tools
A 27610319 Bearing Tool 1
21825617 Dial Indicator 1

B
NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
sition. Main bearing shells removal procedure and
the installation procedure must be completed for
each pair of main bearing shells before the next pair
of main bearing shells are removed.
NOTICE
1. Remove bolts (1) and crankshaft main bearing cap

(2). Note: Place clean engine oil on the crankshaft main
bearings prior to assembly. Ensure that the tabs on
2. Remove the lower half of the crankshaft main the back side of the crankshaft main bearings fit in
bearing from crankshaft main bearing cap (2). the grooves of the crankshaft main bearing caps and
the cylinder block.
Note: The lower main bearing shell is a plain bearing
that has no oil holes.
UENR4511-01 129
4. Place crankshaft main bearing caps (2) in position

on the cylinder block and Install bolts (1). Evenly
tighten the bolts in order to pull the caps into
position. Ensure that the caps are correctly
seated.
Note: Do not tap the main bearing caps into position

as the bearing shells may be dislodged.
1. Use Tooling (A) and install the upper halves of the Illustration 218 g03769536
crankshaft main bearings in the cylinder block. Do
not put oil on the back of the crankshaft main 5. Install thrust washers (3) to number 6 main bearing
bearing. in the cylinder block.
Note: The upper main bearing shell has a groove 6. Repeat Step 1 through Step 4 in order to install the
and two oil holes. remaining main bearing shell, main bearing caps,
and bolts.
2. Install the lower halves of the crankshaft main
bearings in crankshaft main bearing caps (2). Do
not put oil on the back of the crankshaft main
bearing.
NOTICE
Crankshaft main bearing caps should be installed
with the part number toward the front of the engine.
Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 that are located on the
bottom surface of the bearing cap. The thrust plate is
used on the number 6 main bearing.
3. Lubricate threads of bolts (1) and the washer face

with clean engine oil or Molylube.
130 UENR4511-01

Typical example
8. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
Illustration 219 g03769517 of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
7. Follow Step 7.a thought Step 7.c to tighten the crankshaft end play. The permissible crankshaft
bolts (1) for the crankshaft main bearing cap. end play is 0.21 ± 0.60 mm (0.0083 ± 0.024 inch).
a. Tighten each bolt (2) to a torque of 95 N·m End By:

(70 lb ft). a. Install the engine oil pump. Refer to
b. Place an index mark on each bolt (2). Tighten - Install” for the correct procedure.
each bolt for an additional 90 ± 5 degrees (1/4
turn). i05986448
c. Rotate the crankshaft in order to ensure that Crankshaft - Remove

there is no binding.
Removal Procedure
Table 55
Required Tools
A T401076 Bracket As 2
UENR4511-01 131
Start By:
a. Remove the front housing. Refer to
Disassembly and Assembly, “Housing (Front) -
b. Remove the flywheel housing. Refer to
procedure.
c. Remove the engine oil pump. Refer to
d. Remove the piston cooling jets. Refer to
Jets - Remove” for the correct procedure.
NOTICE
component life.
1. Check the connecting rod and connecting rod cap

(3) for identification marks and for the location.
Remove bolts (1) from connecting rod cap (3).
Remove the connecting rod cap and connecting
rod bearing (5) (not shown). Position the
connecting rod (7) (not shown) down the cylinder
bore. Repeat Step 1 for the remaining connecting
rod caps.
Note: Ensure that the crankshaft bearing
surfaces are not damaged as the remaining
connecting rod caps are removed.
2. Check the cylinder block and main bearing cap (4)

for identification marks and for the location.
Remove bolts (2) from main bearing cap (4).
Remove the main bearing cap and lower main
bearing (6) (not shown). Repeat Step 1 for the
remaining the main bearing caps.

132 UENR4511-01
7. If necessary, remove the crankshaft gear. Refer to

i05986447
Crankshaft - Install
Table 56
Required Tools
A T401076 Bracket As 2
21825617 Dial Indicator 1
B
NOTICE
component life.

NOTICE
3. Attach Tooling (A) and a suitable lifting device to Ensure that the crankshaft main bearing tabs engage
with the grooves in the block and the crankshaft main
crankshaft (7). The weight of the crankshaft is bearing cap.
4. Remove crankshaft (8) from the cylinder block. 1. Clean the crankshaft and inspect the crankshaft for
5. For number No. 7 main bearing, remove two thrust wear and damage. Refer to Specifications,
washers (9) from the cylinder block. “Crankshaft” for more information. If necessary,
replace the crankshaft or recondition the
6. Remove upper main bearing shell (10) from the crankshaft.
cylinder block.
2. If necessary, install the crankshaft gear. Refer to
Note: The upper main bearing shell has a groove Disassembly and Assembly, “Crankshaft Gear -
and two oil holes. Remove and Install” for the correct procedure.
3. Ensure that parent bores for bearing shells in the
cylinder block are clean. Ensure that the threads
for the main bearing bolts in the cylinder block are
clean and free from damage.
4. Clean the main bearing shells. Inspect the main
bearing shells and the thrust washers for wear and
damage. If necessary, replace the main bearing
shells.
Note: If the main bearing shells are replaced, check
whether oversize main bearing shells were
previously installed.
UENR4511-01 133
5. Install upper main bearing shell (9) into the cylinder 10. Install main bearing shells (6) into main bearing
block. Ensure that the locating tabs for the upper caps (4). Ensure that the locating tabs for the
rear main bearing shells are seated in the slots in lower main bearing shells are correctly seated into
the cylinder block. the slots in the bearing caps.
Note: The upper main bearing shell has a groove Note: The lower main bearing shells are plain
and two oil holes. bearings that do not have oil holes.
6. Lubricate upper main bearing shells (9) with clean 11. Lubricate main bearing shells (6) and lubricate
engine oil. the journals of the crankshaft with clean engine oil.
Install main bearing cap (4) to the cylinder block.
7. Attach Tooling (A) and a suitable lifting device to
crankshaft (7). The weight of the crankshaft is Note: Ensure the correct location and orientation of
approximately 79 kg (175 lb). the main bearing caps. The locating tabs for the
upper and the lower main bearing shells should be on
8. Use the suitable lifting device to install crankshaft
the same side of the engine.
(7) to the cylinder block. Ensure that the
crankshaft bearing surfaces are not damaged 12. Lubricate the threads of bolts (2) with clean
as the crankshaft is installed. engine oil. Lubricate the underside of the heads of
9. Apply clean engine oil to thrust washers (8). Install bolts (2) with clean engine oil.
the thrust washers to number No. 7 main bearing. 13. Install bolts (2) to main bearing cap (4). Evenly
tighten the bolts in order to pull the caps into
position. Ensure that the caps are correctly
seated. Repeat Step 10 through Step 13 to install
remaining main bearing shells, main bearing cap,
and bolts.
Note: Do not tap the main bearing caps into position
as the bearing shells may be dislodged.
134 UENR4511-01
14. Lubricate the connecting rod bearings with clean

engine oil. Ensure that the connecting rod
bearings are correctly locating tabs connecting rod
(7) (not shown) and the connecting rod cap(3).
15. Position connecting rod (7) (not shown) onto
crankshaft.
16. Lubricate connecting rod bearing (5) (not shown)
with clean engine oil. Install connecting rod cap (3)
to connecting rod (7) (not shown). Ensure that the
identification marks are correctly positioned.
17. Install bolts (1) to connecting rod cap (3) and
evenly tighten the bolts in order to pull the
connecting rod cap into position. Repeat Step 14
through Step 17 to install remaining connecting
rod bearing, connecting rod cap, and bolts.
18. Rotate the crankshaft in order to ensure that
UENR4511-01 135

Tightening sequence for the main bearing cap bolts
19. Follow Step 19.a thought Step 19.c to tighten the

bolts (2) for the crankshaft main bearing caps. b. Place an index mark on each bolt (2). Tighten
a. Tighten each bolt (2) to a torque of 95 N·m turn) in the numerical sequence that is shown
(70 lb ft) in the numerical sequence that is in Illustration 226 .
shown in Illustration 226 .
136 UENR4511-01
c. Rotate the crankshaft in order to ensure that


Typical example
21. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
crankshaft end play. The permissible crankshaft
end play is 0.21 ± 0.60 mm (0.0083 ± 0.024 inch).
20. Follow Step through Step to tighten bolts (1) for
the connecting rod caps.
a. Tighten each bolt (1) to a torque of 50 N·m

(36.87800 lb ft).
b. Place an index mark on each bolt. Tighten

turn).
c. Ensure that the installed connecting rod

assembly has tactile side play. Rotate the
crankshaft in order to ensure that there is no
binding.
UENR4511-01 137
End By: Start By:

a. Install the piston cooling jets. Refer to a. Remove the crankshaft. Refer to Disassembly
Disassembly and Assembly, “Piston Cooling and Assembly, “Crankshaft - Remove” for the
Jets - Remove” for the correct procedure. correct procedure.
b. Install the engine oil pump. Refer to
c. Install the flywheel housing. Refer to
procedure.
d. Install the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Install” for
i06031074
Crankshaft Gear - Remove and

Install
Removal Procedure
Table 57 Illustration 229 g03781900
Required Tools
1. Make temporary marks on crankshaft gear (2) for
installation purposes.
- Bearing Puller 1
2. Use Tooling (A) in order to remove crankshaft gear
- Screw 1 (2) from crankshaft (1).
A
- Crossblock 1 3. If necessary, remove key (3) from crankshaft (1).
- Puller Leg 2
Table 58
Required Tools
B - Hot Plate 1
1. Ensure that all components are clean and free

from wear and damage. If necessary, replace any
138 UENR4511-01
End By:
a. Install the crankshaft. Refer to Disassembly
and Assembly, “Crankshaft - Remove” for the
correct procedure.
i05980323
Bearing Clearance - Check
Measurement Procedure
Table 59
Required Tools
Plastigauge (Green)
- 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
Plastigauge (Red)
- 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
2. If necessary, install a new key (3) to crankshaft (1). A
Plastigauge (Blue)
- 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
Hot parts or hot components can cause burns or Plastigauge (Yellow)

personal injury. Do not allow hot parts or compo- - 0.230 to 0.510 mm 1
nents to contact your skin. Use protective cloth- (0.009 to 0.020 inch)
ing or protective equipment to protect your skin.
NOTICE
Note: The crankshaft gear may be a sliding fit on the Keep all parts clean from contaminants.
crankshaft or an interference fit on the crankshaft.
3. Use Tooling (B) to heat crankshaft gear (2) to component life.
150° ± 50°C (302° ± 90°F).
4. Align the keyway on crankshaft gear (2) with key Note: Perkins does not recommend the checking of
(3) in the crankshaft. Install crankshaft gear (2) to the actual clearances of the bearing shells
crankshaft (1). Ensure that the crankshaft gear is particularly on small engines. Checking of the actual
correctly orientated. clearances of the bearing shells is because of the
possibility of obtaining inaccurate results and of
damaging the bearing shell or the journal surfaces.
Each Perkins bearing shell is quality checked for
specific wall thickness.
Note: The measurements should be within
specifications and the correct bearings should be
used. If the crankshaft journals and the bores for the
block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).
UENR4511-01 139
Note: When Tooling (A) is used, the readings can

NOTICE
Lead wire, shim stock or a dial bore gauge can dam- sometimes be unclear. For example, all parts of
age the bearing surfaces. Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
The technician must use Tooling (A) correctly. The within the specification range. Refer to Specifications
following points must be remembered: Manual, “Connecting Rod Bearing Journal” and
Specifications Manual, “Main Bearing Journal” for the
• Ensure that the backs of the bearings and the correct clearances.
bores are clean and dry.
i06546597
• Ensure that the bearing locking tabs are properly
seated in the tab grooves.
Refrigerant Compressor -
• The crankshaft must be free of oil at the contact Remove and Install
points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.
Removal Procedure
Note: Do not allow Tooling (A) to extend over the
Note: Cleanliness is an important factor. Cleaning of
edge of the bearing.
the exterior of the component before the disassembly
2. Use the correct torque-turn specifications in order procedure is carried out will help to prevent dirt from
entering the internal mechanism.
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed. NOTICE
Note: Do not turn the crankshaft when Tooling (A) is nance, testing, adjusting and repair of the product.
installed. Be prepared to collect the fluid with suitable contain-
3. Carefully remove the cap, but do not remove bling any component containing fluids.
Tooling (A). Measure the width of Tooling (A) while
Tooling (A) is in the bearing cap or on the Dispose of all fluids according to local regulations
crankshaft journal. Refer to Illustration 231 . and mandates.

Typical Example
4. Remove all of Tooling (A) before you install the

bearing cap.
140 UENR4511-01
Personal injury can result from contact with

refrigerant.
Contact with refrigerant can cause frost bite.
Keep face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or Illustration 232 g06018824
death.
Typical example of a refrigerant compressor (ports
Do not smoke when servicing air conditioners or may vary)
wherever refrigerant gas may be present.
2. Disconnect the hose assemblies from port (1) and
Use a certified recovery and recycling cart to port (2). Refer to the Original Equipment
properly remove the refrigerant from the air con-
ditioning system. Manufacture (OEM) for the correct procedure.
Note: Cap the hose assemblies with new caps. Plugs

Note: Put identification marks on all lines, on all the ports in the refrigerant compressor with new
hoses, on all wires, and on all tubes for installation plugs.
purposes. Plug all lines, hoses, and tubes. Plugging
3. Disconnect harness assembly (3) from refrigerant
all lines helps to prevent fluid loss and helps to keep
contaminants from entering the system. compressor (4).

position.
UENR4511-01 141
4. Remove the alternator belt. Refer to Disassembly 7. If necessary, follow Step 7.a through Step 7.b to
and Assembly, “Alternator Belts - Remove and remove bracket (5) for the refrigerant compressor
Install” for the correct procedure. from the cylinder block.
5. Remove bolts (6) and bolts (7) from refrigerant a. Remove bolts (8) from bracket (5).
compressor (4).
b. Remove bracket (5) from the water pump.
Note: Support the weight of the refrigerant
compressor on removal of the bolts. Installation Procedure
6. Remove refrigerant compressor (4) from bracket
(5).
1. If necessary, follow Step 1.a through Step 1.c to

install bracket (5) for the refrigerant compressor to
the cylinder block.
142 UENR4511-01
a. Ensure that bracket (5) is clean and free from

wear and damage. If necessary, replace the
bracket.
b. Position bracket (5) onto the water pump.
Install bolts (8) and hand tighten the bolts.

(41 lb ft).

Typical example of a refrigerant compressor (ports
may vary)
6. Connect harness assembly (3) to refrigerant

compressor (4).
7. Remove the caps from hose assemblies and
remove the plugs from the ports of the refrigerant
compressor. Connect the hose assemblies to port
(1) and port (2) . Refer to the OEM for the correct
2. Position refrigerant compressor (4) onto bracket procedure.
(5). 8. Turn the battery disconnect switch to the ON
position.
Note: Support the weight of the refrigerant
compressor.
i05986439
3. Install bolts (6) and bolts (7) to refrigerant

compressor (4).
Atmospheric Pressure Sensor
4. Tighten bolts (6) and bolts (7) to a torque of - Remove and Install
28 N·m (21 lb ft).
5. Install the alternator belt. Refer to Disassembly
and Assembly, “Alternator Belts - Remove and Removal Procedure
NOTICE
component life.
UENR4511-01 143
1. Cut cable strap (3) from harness assembly (1). 1. Install a new O-ring seal (4) (not shown) onto
atmospheric pressure sensor (2).
2. Disconnect harness assembly (1) from
atmospheric pressure sensor (2). 2. Install atmospheric pressure sensor (2). Tighten
the atmospheric pressure sensor to a torque of
3. Remove atmospheric pressure sensor (2).
10 N·m (89 lb in).
4. Remove O-ring seal (4) (not shown) from
3. Connect harness assembly (1) to atmospheric
atmospheric pressure sensor (2).
Installation Procedure 4. Install a new cable strap (3) to harness assembly
(1).
NOTICE
Keep all parts clean from contaminants. Note: Ensure that the cable strap meets Original
Equipment Manufacture (OEM) specifications.
component life.
i05986323
Coolant Temperature Sensor -

Remove and Install
Removal Procedure
NOTICE
and mandates.
144 UENR4511-01
1. Drain the coolant into a suitable container for Installation Procedure

storage or for disposal. Drain the coolant to a level
that is below the coolant temperature sensor.
“Cooling System Coolant (ELC) - Change” for the
correct procedure.
1. Install a new O-ring seal (3) (not shown) to coolant

temperature sensor (1).
2. Install coolant temperature sensor (1) to the
cylinder head. Tighten the coolant temperature
sensor to a torque of 20 N·m (177 lb in).
2. Disconnect harness assembly (2) from coolant
temperature sensor (1). 3. Connect harness assembly (2) to coolant
3. Remove coolant temperature sensor (1) from the
cylinder head. 4. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
4. Remove O-ring seal (3) (not shown) from Remove
(ELC) - Change” for the correct procedure.
coolant temperature sensor (1) from the cylinder
head.
i05986418
Engine Oil Pressure Sensor -

Remove and Install
Removal Procedure
NOTICE
and mandates.
UENR4511-01 145
NOTICE
component life.
1. Install a new O-ring seal (1) (not shown) onto the

adapter.
2. Install engine oil pressure sensor (2). Tighten the
engine oil pressure sensor to a torque of 10 N·m
Illustration 242 g03779490 (89 lb in).
1. Disconnect harness assembly (3) from engine oil 3. Connect harness assembly (1) to engine oil
pressure sensor (2). pressure sensor (2).
2. Remove engine oil pressure sensor (2). i05986440
3. Remove O-ring seal (1) (not shown) from the
adapter. Fuel Pressure Sensor -
Installation Procedure Remove and Install
NOTICE
Removal Procedure
and mandates.
NOTICE
component life.
146 UENR4511-01

Typical example Typical example
1. Slide the locking tab into the unlocked position. 1. Install a new O-ring seal (3) on fuel pressure
Disconnect harness assembly (1) from fuel sensor (2).
2. Install fuel pressure sensor (2) to fuel filter base
2. Remove fuel pressure sensor (2) from fuel filter (4). Tighten the fuel pressure sensor to a torque of
base (4). 10 N·m (89 lb in).
3. Remove O-ring seal (3) from fuel pressure sensor 3. Connect harness assembly (1) to fuel pressure
(2). sensor (2). Slide the locking tab into the locked
position.
i06543397
NOTICE
Keep all parts clean from contaminants. Fuel Pressure Sensor -
component life. Remove and Install
(Option 2)
Removal Procedure
NOTICE
and mandates.
UENR4511-01 147
NOTICE
component life.

Typical example
1. Install a new O-ring seal (4) (not shown) on elbow

connection (5).
2. Install fuel pressure sensor (3) to elbow connection
(5). Tighten the fuel pressure sensor to a torque of
Typical example 10 N·m (89 lb in).
1. Cut cable strap (2). 3. Connect harness assembly (1) to fuel pressure
sensor (3). Slide the locking tab into the locked
2. Slide the locking tab into the unlocked position. position.
Disconnect harness assembly (1) from fuel
pressure sensor (3). 4. Secure harness assembly (1) with a new cable
strap (2).
3. Remove fuel pressure sensor (3) from elbow
connection (5). i05986297
4. Remove O-ring seal (4) (not shown) from elbow
connection (5). Fuel Temperature Sensor -
Installation Procedure Remove and Install
NOTICE
Removal Procedure
and mandates.
148 UENR4511-01
NOTICE
component life.

Typical example
1. Install a new O-ring seal (4) to fuel temperature

sensor (2).
2. Install fuel temperature sensor (2) to the fuel filter
base (3). Use a deep socket to tighten the fuel
Typical example temperature sensor to a torque of 20 N·m
(15 lb ft).
1. Disconnect harness assembly (1) from fuel
temperature sensor (2). 3. Connect harness assembly (1) to fuel temperature
sensor (2).
2. Use a deep socket in order to remove fuel
temperature sensor (2) from fuel filter base (3). i06031075
3. Remove O-ring seal (4) from fuel temperature
sensor (2). Injection Actuation Pressure
Installation Procedure Sensor - Remove and Install
NOTICE
Removal Procedure
and mandates.
UENR4511-01 149
4. If necessary, follow Step 2.a through Step 2.c in

NOTICE
Keep all parts clean from contaminants. order to remove elbow connection (4).
Contaminants may cause rapid wear and shortened a. Make temporary marks on elbow connection
component life. (4).
b. Loosen locking nut (5) and remove elbow

connection (4) from the cylinder head.
c. Remove O-ring seal (6) (not shown).
NOTICE
component life.
1. Ensure that all the components are free from wear

or damage. Replace any component that is worn
or damaged.
1. Disconnect harness assembly (1) from injection

actuation pressure sensor (2).
2. Use a suitable tool to remove injection actuation
pressure sensor (2) from elbow connection (4).
150 UENR4511-01
3. Install a new O-ring seal (1) (not shown) to

injection actuation pressure sensor (2).
4. Use a suitable tool to install injection actuation
pressure sensor (2) to elbow connection (4).
Tighten the injection actuation pressure sensor to
a torque of 20 N·m (177 lb in).
5. Connect harness assembly (1) to injection
actuation pressure sensor (2).
i06544818
Speed/Timing Sensor -
Remove and Install
Removal Procedure
Start By:
a. If necessary, remove the air compressor. Refer
to Disassembly and Assembly, Air
correct procedure.
Removal Procedure
2. If necessary, follow Step 2.a through Step 2.c in

order to install elbow connection (4).
a. Install a new O-ring seal (6) (not shown) to

elbow connection (4).
b. Install elbow connection (4) to the cylinder

head and align with temporary marks.
c. Tighten locking nut (5) to a torque of 30 N·m Illustration 254 g03776761

(266 lb in). Ensure that the elbow connection Typical example
remains align after the locking nut is tightened.
UENR4511-01 151
1. Disconnect harness assemblies (2) from speed/ 1. Apply Tooling (A) to new O-ring seals (6) prior to
timing sensors (1). installation. Install new O-ring seals (6) to speed/
timing sensors (1).
2. Remove bolt (5), washer (4), and bracket (3).
2. Install speed/timing sensors (1) to the front
Note: Make a note of the orientation of the bracket. housing.
3. Carefully remove speed/timing sensors (1) from 3. Install bolt (5) to washer(4). Position bracket (3) to
the front housing. the front housing. Install bolt (5) to bracket (3).
4. Remove the O-ring seals (6) from speed/timing 4. Tighten bolt (5) to a torque of 28 N·m (248 lb in).
sensors (1).
5. Connect harness assemblies (2) onto speed/timing
Installation Procedure sensors (1).
Table 60 End By:
Required Tools
a. If necessary, install the air compressor. Refer
Tool Part Number Part Description Qty to Disassembly and Assembly, Air
A - Loctite 575 1 correct procedure.
i05986307
NOTICE
Keep all parts clean from contaminants. Inlet Manifold Temperature
component life. Sensor - Remove and Install
Removal Procedure
NOTICE
component life.

Typical example
152 UENR4511-01
1. Disconnect harness assembly (2) from inlet 1. Install a new O-ring seal (3) to inlet manifold
manifold temperature sensor (1). temperature sensor (1).
2. Use a deep socket to remove inlet manifold 2. Use a deep socket to install inlet manifold
temperature sensor (1). temperature sensor (1). Tighten the inlet manifold
temperature sensor to a torque of 20 N·m
3. Remove O-ring seal (3) from inlet manifold
(15 lb ft).
Installation Procedure temperature sensor (1).
NOTICE i05986301
Contaminants may cause rapid wear and shortened Inlet Manifold Pressure Sensor
component life.
- Remove and Install
Removal Procedure
NOTICE
component life.
UENR4511-01 153
NOTICE
component life.
1. Cut cable strap (2) from harness assembly (1).

manifold pressure sensor (3).
3. Use a suitable tool to remove inlet manifold
pressure sensor (3) from adapter (5) in the
cylinder head.
4. Remove O-ring seal (4) (not shown) from adapter 1. If necessary, install a new O-ring seal (6) (not
(5). shown) to adapter (5). Install the adapter to the
cylinder head. Tighten the adapter to a torque of
5. If necessary, remove adapter (5) from the cylinder
40 N·m (30 lb ft).
head. Remove O-ring seal (6) (not shown).
2. Install a new O-ring seal to adapter (5).
154 UENR4511-01
3. Use a suitable tool to install inlet manifold pressure

sensor (1) to adapter (5) in the cylinder head.
Tighten the inlet manifold pressure sensor to a
pressure sensor (1). Install a cable strap (2) to the
harness assembly.
Note: Ensure that the cable strap meets Original
Equipment Manufacture (OEM) specifications.
i05986200
V-Belts - Remove and Install

(Charging Alternator Drive Belts)
Removal Procedure
1. If necessary, remove the engine fan guards. Refer Illustration 263 g03778318
to the Original Equipment Manufacture (OEM) for Typical example
2. Loosen bolt (1) and bolt (2). Loosen nut (3).
Note: Mark the direction of rotation of the belt if the
belt is to be reused. 3. Loosen bolt (4). Loosen nut (5) and nut (6).
4. Remove alternator belts (7).
1. Ensure that the pulleys are clean. Ensure that the
pulleys are free from dirt and build up from the old
belts.

Typical example

Typical example
UENR4511-01 155
9. If necessary, install the engine fan guards. Refer to

the OEM for the correct procedure.
i05986217
V-Belts - Remove and Install

(Water Pump Drive Belt)
Removal Procedure
Start By:
a. Remove the V-Belts for the charging alternator.
Refer to Disassembly and Assembly, “V-Belts -
Remove and Install (Charging Alternator Drive
Belts)” for the correct procedure.
1. If necessary, remove the engine fan guards. Refer
to the Original Equipment Manufacture (OEM) for
Typical example 2. Mark the direction of rotation of the belt if the belt is
to be reused.
2. Position alternator belts (7). Used belts should be
installed in the original direction of rotation.
3. Adjust nut (5) and nut (6) in order to increase or
decrease the tension of belts (7). Refer to
Operation and Maintenance Manual, “Belts -
Inspect/Adjust/Replace” for the correct tension.
4. With the correct applied tension on belts (7),
tighten nut (5) and nut (6) securely.
5. Tighten bolt (1) to a torque of 89 N·m (65 lb ft).
7. Tighten the bolt and nut (3) to a torque of 89 N·m
(65 lb ft).

Typical example
3. Loosen bolt (2) and bolt (4).

4. If necessary, install a 1/2" square drive tool into
Hole (X) in plate (3) in order to adjust pulley
assembly (1). From the front of the engine, turn
the tool in a clockwise direction.
5. Remove belt (5).
156 UENR4511-01
6. Release the pressure on the 1/2" square drive tool 7. If the engine has guards, install the guards. Refer
and remove the 1/2" square drive tool from Hole to the OEM for the correct procedure.
(X).
i06544870
Alternator Belt - Remove and
Install
Removal Procedure
1. If the engine has guards, remove the guards. Refer
Note: Mark the direction of rotation of the alternator
belt if the belt will be reused.

Typical example
1. Ensure that the pulleys are clean. Ensure that the

pulleys are free from dirt and build up from the old
belt.
2. Install a 1/2" square drive tool into Hole (X) in plate
(3).
3. Position belt (5). Ensure that the belt is centered
on all pulleys. A used belt should be installed in
the original direction of rotation.
Note: The ribs on the belt must be located into the Illustration 268 g06016831
grooves of all pulleys. Typical example
4. From the front of the engine, turn the 1/2" square 2. Install a 1/2" square drive tool into Hole (X) in
drive tool in a clockwise direction in order to adjust tensioner (2). From the front of the engine, turn the
pulley assembly (1). tool in a clockwise direction.
5. Release the pressure on the 1/2" square drive tool 3. Remove alternator belt (1).
until the belt is tensioned. Remove the 1/2" square
drive tool from Hole (X). 4. Release the pressure on the 1/2" square drive tool
and remove the 1/2" square drive tool from Hole
6. With the correct tension on the belt, tighten bolt (2) (X).
and bolt (4). Tighten bolts to a torque of 28 N·m
(248 lb in).
UENR4511-01 157
Installation Procedure 6. If the engine has guards, install the guards. Refer
to the OEM for the correct procedure.
i06547498
Idler Pulley - Remove and

Install
(Grooved Idler Pulley)
Removal Procedure
Start By:
a. Remove the alternator belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove and Install”.
NOTICE
Typical example
1. Ensure that the belt tensioner, pulleys, and all

guide rollers are clean. Ensure that the pulleys
and guide rollers are free from dirt and build up
from the old belt.
2. Ensure that all components of the belt tensioner,
pulleys, and guide rollers are clean and free from
wear and damage. If necessary, replace any
Refer to Disassembly and Assembly, “Belt
Tensioner - Remove and Install” for the correct
procedure.
Refer to Disassembly and Assembly, “Idler Pulley
(Grooved Idler Pulley) - Remove and Install” for
3. Install a 1/2" square drive tool into Hole (X) in
tensioner (2). From the front of the engine, turn the
tool in a clockwise direction.
4. Position alternator belt (1). Ensure that the Illustration 270 g06019350
alternator belt is centered on all pulleys. A used
alternator belt should be installed in the original 1. Make a temporary mark on idler pulley (2) to
direction of rotation. identify the correct orientation and the position.
Note: The ribs on the alternator belt must be located 2. Loosen bolt (1) and remove idler pulley (2).
into the grooves of all pulleys.
5. Release the pressure on the 1/2" square drive tool

until the alternator belt is tensioned. Remove the
1/2" square drive tool from Hole (X).
158 UENR4511-01
Installation Procedure 2. Remove the alternator belt. Refer to Disassembly

and Assembly, “Alternator Belt - Remove and
NOTICE Install.” for the correct procedure.
component life.
1. Ensure that all components of the idler pulley are

clean and free from wear and damage. If
necessary, replace any components that are worn
or damaged.
3. Make a temporary mark on belt tensioner (3) to

identify the correct orientation and the position.
4. Loosen bolt (2) sufficiently to remove belt
tensioner (3) from mounting bracket (1).
5. Remove belt tensioner (3) from mounting bracket
(1).
2. Position idler pulley (2) onto bracket (3). Tighten
bolt (1) hand tight. 1. Ensure that all components of the belt tensioner
are clean and free from wear and damage. If
3. Tighten bolt (3) to a torque of 55 N·m (41 lb ft). necessary, replace any components that are worn
End By: or damaged.
a. Install the alternator belt. Refer to Disassembly

Install”.
i06547445
Belt Tensioner - Remove and

Install
Removal Procedure
1. If the engine has guards, remove the guards. Refer
UENR4511-01 159
2. Position belt tensioner (3) on mounting bracket (1).

Tighten bolt (2) finger tight.
4. Install the alternator belt. Refer to Disassembly
Install.” for the correct procedure.
5. If the engine has guards, install the guards. Refer
to the OEM for the correct procedure.
i05986264
Fan - Remove and Install
Removal Procedure
1. If necessary, remove the engine fan guards. Refer
the correct procedure. Illustration 275 g03780757
2. Remove bolts (2) from fan assembly (1). Support

the fan assembly as the bolts are removed.
Note: Ensure that the radiator is protected during

removal of the fan assembly.
3. Remove fan assembly (1). Note orientation of the

fan assembly for installation purposes.
order to remove adapter (4).
a. Remove V-belts belts (7). Refer to

Disassembly and Assembly, “V-Belts -
160 UENR4511-01
Remove and Install (Charging Alternator Drive f. Install V-belts belts (7). Refer to Disassembly
Belts)” for the correct procedure. and Assembly, “V-Belts - Remove and Install
(Charging Alternator Drive Belts)” for the
b. Remove bolts (3) from adapter (4). Support correct procedure
the fan adapter as the bolts are removed.
c. Remove fan adapter (4) from pulley (6).
d. If necessary, remove pulley (6) from the fan

drive assembly.
e. Remove O-ring seal (5) (not shown).
1. Ensure that all the components are free wear or
damage. If necessary replace any component that
is worn or damaged.
3. Install fan assembly (1). Ensure that the fan

assembly is orientated.
4. Install bolts (2) to fan assembly (2). Support the
fan assembly as the bolts are installed.
Note: Ensure that the radiator is protected during

installation of the fan assembly.

6. If necessary, install the engine fan guards. Refer to
Illustration 276 g03780757 the OEM for the correct procedure.
2. If necessary, follow Step 2.a through Step 2.f in i05986429

order to install adapter (4).
Fan Drive - Remove
a. If necessary, install pulley (6) to the fan drive
assembly. Ensure that the bolt holes are
aligned.
Removal Procedure
b. Install a new O-ring seal (5) (not shown).
1. Remove the fan. Refer to Disassembly and
c. Install fan adapter (4) onto pulley (5) and align Assembly, “Fan - Remove and Install” for the
the bolt holes. correct procedure.
d. Install bolts (3) to adapter (4). Support the fan
adapter as the bolts are installed.
e. Tighten bolts (3) to a torque of 47 N·m

(416 lb in).
UENR4511-01 161
b. Remove bolt (6) and spacer (5) from the

alternator adjusting bracket.
c. Remove bolts (4) from bracket (3). Support the

bracket as the bolts are removed.
d. Remove bracket (3) from the cylinder head.
i05986426
Fan Drive - Disassemble
Table 61
Required Tools
Start By:
2. Make temporary marks on fan drive (2) and
bracket (3) for installation purposes. a. Remove the fan drive. Refer to Disassembly
and Assembly, “Fan Drive - Remove” for the
3. Remove bolts (1) from fan drive (2). Support the correct procedure.
fan drive as the bolts are removed.
NOTICE
4. Remove fan drive (2) from bracket (3). Keep all parts clean from contaminants.
component life.

order to remove bracket (3).
a. If necessary, remove the Original Equipment

Manufacture (OEM) radiator support brackets.
162 UENR4511-01
1. Place the fan drive assembly in a suitable support.

NOTICE
2. Remove bolt (13) and washer (14). Keep all parts clean from contaminants.
3. Remove plate (12) and bearing (11). Contaminants may cause rapid wear and shortened
component life.
4. Remove hub assembly (9) and pulley (3).
5. Remove spacer (5) from hub assembly (9)
6. Use a suitable tool to remove seal (4) from hub
assembly (9). Remove bearing (6) and spacer (8).
7. Position hub assembly (9) on a suitable press. Use
Tooling (A) and the press to remove bearing cup
(7) and bearing cup (10) from the hub assembly
(9).
8. If necessary, remove spring pin (2) from shaft (1).
i05986425
Fan Drive - Assemble
Assembly Procedure
Table 62
Required Tools
B - Bearing Lubricant 1
UENR4511-01 163
1. If necessary, install spring pin (2) to shaft (1).

2. Position hub assembly (9) on a suitable press. Use
Tooling (A) and the press to install bearing cup (7)
and bearing cup (10) to hub assembly(9). Ensure
that the bearing cups are correctly seated into the
hub assembly.
3. Apply Tooling (B) to bearing (6). Install the bearing
into hub assembly(9).
4. Use a suitable tool to install seal (4) to hub
assembly (9). Ensure that the seal is correctly
installed. Install spacer (8) to seal (4).
5. Apply Tooling (B) to shaft (1).
6. Position pulley (3) onto hub assembly (9). Ensure
that the pulley is correctly orientated on the hub
assembly.
7. Install pulley (3) and hub assembly (9) onto shaft
(1). Install shaft (1).
8. Install plate (12) to shaft (1). Ensure that the hole
in plate is correctly located into the spring pin.
9. Install washer (14) and bolt (13). Tighten the bolt to
a torque of 100 N·m (74 lb ft). Ensure that the hub
assembly (9) rotate freely and with no binding.
164 UENR4511-01
End By:
a. Install the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Install” for the correct
procedure.
i05986427
Fan Drive - Install

2. Position fan drive (2) onto bracket (3) and align

with temporary marks.
3. Install bolts (1) to fan drive (2). Support the fan
drive as the bolts are removed.
5. Install the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install” for the
correct procedure.
Illustration 282 g03780787 i05986352
1. If necessary, follow Step 1.a through Step 1.e in Electronic Control Module -
order to install bracket (3). Remove and Install
a. Position bracket (3) onto the cylinder head.
b. Install bolts (4) to bracket (3). Support the

bracket as the bolts are install.
Removal Procedure
1. If a replacement Electronic Control Module (ECM)
is to be installed, the replacement ECM must be
(41 lb ft).
programmed with the correct information. Refer to
d. Install bolt (6) and spacer (5) to the alternator Troubleshooting Guide, “ECM - Replace” for the
adjusting bracket. correct procedure.
e. If necessary, install the Original Equipment
position.
Manufacture (OEM) radiator support brackets.
UENR4511-01 165
3. Cut cable strap (1), cable strap (3), cable strap (5), 10. If necessary, follow Step 2.c through Step 10.c in
and cable strap (7). order to disassemble ECM (11).
4. Loosen Allen head screw (9) until harness a. Remove spacers (17) and isolator mounts (18)
assembly (4) can be disconnected from the ECM from ECM (11).
(11).
b. Remove bolt (14) (not shown) and bracket
5. Position harness assemblies (4) away from ECM
(13).
(11).
6. Loosen Allen head screw (10) until Original c. Remove bolt (16) and bracket (16).
Equipment Manufacture (OEM) harness assembly
(6) can be disconnected from the ECM (11). Installation Procedure
7. Position OEM harness assembly (4) away from 1. Ensure that all components for the ECM are free
ECM (11). from wear or damage. Replace any component
8. Remove bolts (12) and the washers from ECM (11)
ensure that ground strap (2) is not damaged as the
bolts are removed. Remove brackets (8). Support
the ECM as the bolts are removed.
9. Remove ECM (11) from the cylinder block.
166 UENR4511-01
2. If necessary, follow Step 2.a through Step 2.d in 3. Position electronic control module (4) onto the
order to assemble ECM (11). cylinder block. Install the washers and bolts (12)
and brackets (8) to ECM (11). Support the ECM as
a. Install isolator mounts (18) to ECM (11). Install the bolts are installed. Ensure that the brackets
spacers (17) to the isolator mounts. are installed into the correct positions.
b. Position bracket (13) onto ECM (11). Install 4. Tighten bolts (12) to a torque of 28 N·m (248 lb in)
bolt (14) (not shown) hand tight. Ensure that . Ensure that ground strap (2) is not damaged as
the bracket is correctly orientated. the bolts are tightened.
c. Position bracket (15) onto ECM (11). Install 5. Position harness assemblies (4) onto ECM (11).
bolt (16) (not shown) hand tight. Ensure that 6. Tighten Allen head screw (9) until harness
the bracket is correctly orientated. assembly (4) is connected onto ECM (11).
d. Tighten bolt (16) and bolt (14) (not shown) to a Note: Care must be taken in order to avoid damage
torque of 6.5 N·m (57 lb in). to the connector pins during installation of the
harness assembly.
7. Position OEM harness assembly (4) onto ECM

(11).
8. Tighten Allen head screw (10) until harness
assembly (6) is connected onto ECM (11).
Note: Care must be taken in order to avoid damage

to the connector pins during installation of the
harness assembly.
9. Tighten Allen head bolt (9) and Allen head screw

(10) to a torque of 6 N·m (53 lb in).
10. Install new cable strap (1), cable strap (3), cable
strap (5), and cable strap (7) to the harness
assemblies.
11. Turn the battery disconnect switch to the ON
position.
UENR4511-01 167
12. If new ECM has been installed, programmed the

new ECM configuration data. Refer to
Troubleshooting Guide, “ECM - Replace” for the
correct procedure.
i05986315
Alternator - Remove and Install
Removal Procedure
Start By:
a. Remove the belt. Refer to Operation and
Maintenance Manual, “Belts - Inspect/Replace”
Personal injury can result from failure to discon- Illustration 288 g03749697
nect the battery.
First, disconnect the negative battery cable. 2. Remove the guard from the radiator in order to
Then, disconnect the positive battery cable. gain access to alternator (3). Refer to the Original
Equipment Manufacture (OEM) for the correct
A positive power lead can cause sparks if the bat- procedure.
tery is not disconnected. Sparks can possibly re-
sult in battery explosion or fire. 3. Place identification marks on all of the harness
assemblies. Disconnect the harness assemblies
from alternator (3).
NOTICE
Keep all parts clean from contaminants. 4. Remove bolt (1) and spacer (2) from the alternator
belt adjuster.
component life. 5. Remove the nut and bolt (5) and bolt (7). Support
the alternator (3) as the nut and bolt and the bolt
1. Turn the battery disconnect switch to the OFF are removed.
position. 6. Remove alternator (3) from bracket (6).
7. If necessary, remove pulley (4) from alternator (3).
168 UENR4511-01
8. If necessary, follow Step 2.c through Step 8.c to 2. If necessary, follow Step 2.a through Step 2.d to
remove bracket (6). install bracket (5).
a. Remove the spacer and bolts (9) and the a. If necessary, install ring dowels (7) from the
spacer and bolt (10) from bracket (6). water pump. Ensure that the ring dowels are
correctly seated into the water pump.
b. Remove bracket (6) from the water pump.
b. Install bracket (5) from the water pump.
c. If necessary, remove ring dowels (8) from the Ensure that the bracket is correctly seated
water pump. onto ring dowels (7).
Installation Procedure c. Install the spacer and bolts (8) and the spacer
and bolt (9) to bracket (5).
NOTICE
Keep all parts clean from contaminants. d. Tighten bolts (8) and bolt (9) to a torque of
Contaminants may cause rapid wear and shortened 55 N·m (41 lb ft).
component life.
1. Ensure that the alternator and the bracket are free

from wear or damage. Replace any component
UENR4511-01 169

position.
i06547272
Alternator - Remove and Install

(High Mounted Alternator)
Removal Procedure
Start By:
a. Remove the belt. Refer to Disassembly and
Assembly, “Alternator Belt - Remove and
Personal injury can result from failure to discon-

Illustration 291 g03749697 nect the battery.
3. If necessary, install pulley (4) on alternator (3). First, disconnect the negative battery cable.
Then, disconnect the positive battery cable.
Install the nut and tighten the nut to a torque of
127 N·m (94 lb ft). A positive power lead can cause sparks if the bat-
4. Position alternator (3) onto bracket (6). sult in battery explosion or fire.
5. Install the nut and bolt (5) and bolt (7). Support the
alternator (3) as the nut and bolt and the bolt are
installed. NOTICE
6. Install bolt (1) and spacer (2) to the alternator belt
adjuster.
component life.
7. Connect the harness assemblies from alternator
(3). 1. Turn the battery disconnect switch to the OFF
Tighten the nut to a torque of 4 N·m (35 lb in). position.
Tighten the nut to a torque of 18 N·m (159 lb in).

8. Install the belt. Refer to Operation and
Maintenance Manual, “Belts - Inspect/Replace” for
9. Tighten the nut and bolt (5), bolt (7), and bolt (1) to
a torque of 55 N·m (41 lb ft).
170 UENR4511-01
6. Remove alternator (4) from the alternator brackets.

7. If necessary, remove pulley (8) from alternator (4).
2. Remove the guard from the radiator to gain access

to alternator (4). Refer to the Original Equipment Illustration 294 g06018886
Manufacture (OEM) for the correct procedure.
8. Follow Step 9 through Step 12 to remove bracket
3. Place identification marks on all the harness
(9) and bracket (14).
assemblies. Disconnect the harness assemblies
from alternator (4). 9. Remove bolts (10) and washers (11) from bracket
(9).
4. Remove bolts (1), washers (2), and nuts (3) from
the alternator bracket. 10. Remove bracket (9).
11. Remove bolts (12) and washers (13) from bracket
(14).
12. Remove bracket (14).
NOTICE
component life.
1. Ensure that the alternator and the brackets are

free from wear or damage. Replace any
5. Remove nut (7), washers (6) and bolt (5). Support

are removed.
UENR4511-01 171
2. Position bracket (14). Install washers (13) and

bolts (12) finger tight.
3. Position bracket (9). Install washers (11) and bolts
(10) finger tight.
4. If necessary, install pulley (8) on alternator (4).

Install the nut and tighten the nut to a torque of
127 N·m (94 lb ft).
5. Position alternator (4) onto bracket (14).
6. Install bolt (7), washers (6), and nut (5). Support
are installed.
7. Install bolts (1), washers (2) and nuts (3) to bracket
(9).
8. Connect the harness assemblies to alternator (4).
172 UENR4511-01
Tighten bolts (10) and bolts (12) to a torque of

55 N·m (41 lb ft).
Tighten nut (5) and nuts (3) to a torque of 105 N·m
(77 lb ft).
9. Install the belt. Refer to Disassembly and
Assembly, “Alternator Belt - Remove and Install”
position.
i05986351
Electric Starting Motor -

Remove and Install
Removal Procedure
Table 63 Illustration 298 g03774291
Required Tools
A - Lifting Sling 2
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-
sult in battery explosion or fire.

position.
2. Place identification marks on all harness assembly

that is connected to electric starting motor (4) and
the solenoid
3. Disconnect harness assembly (1).
4. Remove nut (2) and remove the earth strap.
5. Remove nut (3) and remove the cables.
electric starting motor (4). The weight of electric
starting motor (1) is approximately 44 kg (97 lb).
7. Remove bolts (5) from electric starting motor (4).
UENR4511-01 173
8. Use the suitable lifting device to remove electric

starting motor (1).
10. Remove Tooling (A) and the suitable lifting device
from electric starting motor (4).
1. Ensure that all components for the electric starting
motor are free from wear or damage. Replace any

electric starting motor (4). The weight of electric
starting motor (1) is approximately 44 kg (97 lb).
electric starting motor (4). Ensure that the O-ring
seal is correctly installed onto the electric starting
motor.
4. Use the suitable lifting device to install electric
starting motor (1).
5. Install bolts (5) to electric starting motor (4) hand
tight.
174 UENR4511-01
6. Remove Tooling (A) and the suitable lifting device

from electric starting motor (4).
7. Tighten bolts (5) to a torque of 215 N·m (159 lb ft). Do not disconnect the air lines until the air pres-
sure in the system is at zero. If hose is discon-
8. Connect harness assembly (1). nected under pressure it can cause personal
injury.
9. Install the earth strap onto electric starting motor
(4) and install nut (2). Tighten the nut to a torque of 1. Remove the air pressure from the air tank and
25 N·m (221 lb in). Ensure that the earth strap is drain the coolant from the cooling system. Refer to
not strained as the nut is tightened. Operation and Maintenance Manual for the correct
10. Install the cables onto electric starting motor (4) procedure.
and install nut (3). Tighten the nut to a torque of
25 N·m (221 lb in). Ensure that the cables are not
strained as the nut is tightened.
position.
i06544850
Air Compressor - Remove and

Install
Removal Procedure
Do not disconnect the air lines until the air pres-

sure in the system is at zero. If hose is discon-
nected under pressure it can cause personal
injury. Illustration 302 g01028440

NOTICE (3) from the air compressor.
Contaminants may cause rapid wear and shortened (4) from the air compressor.
component life.
4. Attach a suitable lifting device to the air
compressor. The weight of the air compressor is
NOTICE approximately 23 kg (51 lb).
tained during performance of inspection, mainte- 5. Remove the mounting bracket for the air
nance, testing, adjusting and repair of the product. compressor by using the following procedure:
and mandates.
Note: Put identification marks on all hoses, on all

hose assemblies and on all tube assemblies for
installation purposes. Plug all hose assemblies and
tube assemblies. Plugging all hose assemblies and
tube assemblies helps to prevent fluid loss and also
helps to keep contaminants from entering the
system.
UENR4511-01 175
Table 64
Required Tools
A - Loctite 242 1
NOTICE
component life.
a. Remove bolts (5) that fasten the mounting

bracket to the air compressor.
b. Remove bolts (6) that fasten the mounting

bracket to the cylinder block. Remove the
mounting bracket for the air compressor.
1. Install a suitable lifting device to the air

compressor. The weight of the air compressor is
2. Inspect the condition of the integral seal. Replace
the integral seal, if necessary. Install the integral
seal between air compressor (8) and the timing
gear housing.
3. Position air compressor (8) in the front housing.
Ensure that the drive gear engages correctly with
the gear in the front housing.
4. Apply Tooling (A) to the threads of bolts (7). Install
bolts (7). Tighten bolts (7) to a torque of
6. Remove bolts (7), air compressor (8), and the 100 ± 20 N·m (75 ± 15 lb ft).
integral seal from the timing gear housing. 5. Install the mounting bracket for the air compressor
by using the following procedure:
176 UENR4511-01

a. Position the bracket for the air compressor

6. Connect hose assembly (4) to the air compressor.
and install bolts (5) and bolts (6) finger tight.
Connect the clip that holds hose assembly (4) to
NOTICE the air compressor, if necessary. Tighten the bolt
A loose compressor bracket can lead to a broken that holds the clip for the oil hose assembly to a
front cover and can damage the front gear train of the torque of 28 ± 7 N·m (21 ± 5 lb ft).
engine.
7. Connect hose assembly (1) and hose assembly (3)
to the air compressor.
b. Tighten bolts (5) to a torque of 60 ± 12 N·m
(44 ± 9 lb ft). Tighten bolts (6) to a torque of 8. Connect hose assembly (2) to the air compressor.
60 ± 12 N·m (44 ± 9 lb ft). Remove the 9. Fill the cooling system with coolant to the correct
suitable lifting device and Tooling (A). level. Refer to the Operation and Maintenance
Manual for the correct filling procedure.
UENR4511-01 177
Index Section
Index
A Installation Procedure .................................... 137
Removal Procedure ....................................... 137
Air Cleaner - Remove and Install ..........................27 Crankshaft Main Bearings - Install (Crankshaft
Installation Procedure ......................................28 in Position)...................................................... 128
Removal Procedure .........................................27 Installation Procedure .................................... 128
Air Compressor - Remove and Install.................. 174 Crankshaft Main Bearings - Remove
Installation Procedure .................................... 175 (Crankshaft in Position).................................... 127
Removal Procedure ....................................... 174 Removal Procedure ....................................... 127
Alternator - Remove and Install .......................... 167 Crankshaft Rear Seal - Install...............................68
Installation Procedure .................................... 168 Installation Procedure ......................................68
Removal Procedure ....................................... 167 Crankshaft Rear Seal - Remove ...........................68
Alternator - Remove and Install (High Mounted Removal Procedure .........................................68
Alternator)....................................................... 169 Cylinder Block Cover - Remove and Install............84
Removal Procedure ....................................... 169 Removal Procedure .........................................84
Alternator Belt - Remove and Install.................... 156 Cylinder Head - Install ....................................... 102
Installation Procedure .................................... 157 Installation Procedure .................................... 102
Removal Procedure ....................................... 156 Cylinder Head - Remove......................................98
Atmospheric Pressure Sensor - Remove and Removal Procedure .........................................98
Install ............................................................. 142 Cylinder Liner - Install ........................................ 119
Removal Procedure ....................................... 142 Cylinder Liner - Remove .................................... 118
B
Bearing Clearance - Check ................................ 138 D
Measurement Procedure ................................ 138 Disassembly and Assembly Section .......................5
Belt Tensioner - Remove and Install.................... 158
Installation Procedure .................................... 158
Removal Procedure ....................................... 158 E
Electric Starting Motor - Remove and Install ........ 172
C Installation Procedure .................................... 173
Camshaft - Install .............................................. 110 Electronic Control Module - Remove and Install... 164
Camshaft - Remove .......................................... 108 Removal Procedure ....................................... 164
Removal Procedure ....................................... 108 Electronic Unit Injector - Install .............................19
Camshaft Bearings - Install ................................ 113 Installation Procedure ......................................19
Installation Procedure .................................... 113 Electronic Unit Injector - Remove..........................17
Camshaft Bearings - Remove ............................ 113 Removal Procedure .........................................17
Removal Procedure ....................................... 113 Electronic Unit Injector Sleeve - Install ..................23
Camshaft Gear - Remove and Install .................. 111 Installation Procedure ......................................23
Installation Procedure .................................... 112 Electronic Unit Injector Sleeve - Remove ..............21
Connecting Rod Bearings - Install....................... 126 Engine Lifting Bracket - Remove and Install ..........60
Connecting Rod Bearings - Remove ................... 125 Removal Procedure .........................................60
Removal Procedure ....................................... 125 Start By...........................................................60
Coolant Temperature Sensor - Remove and Engine Oil Filter Base and Oil Cooler - Install ........43
Install ............................................................. 143 Installation Procedure ......................................43
Installation Procedure .................................... 144 Engine Oil Filter Base and Oil Cooler - Remove.....41
Crankcase Breather - Remove and Install .............83 Engine Oil Pan - Remove and Install................... 115
Installation Procedure ......................................83 Installation Procedure .................................... 116
Removal Procedure .........................................83 Removal Procedure ....................................... 115
Crankshaft - Install ............................................ 132 Engine Oil Pressure Sensor - Remove and
Installation Procedure .................................... 132 Install ............................................................. 144
Crankshaft - Remove......................................... 130 Installation Procedure .................................... 145
Crankshaft Front Seal - Install ..............................75 Engine Oil Pump - Assemble................................49
Installation Procedure ......................................75 Assembly Procedure ........................................49
Crankshaft Front Seal - Remove ..........................74 Engine Oil Pump - Disassemble ...........................47
Removal Procedure .........................................74 Disassembly Procedure ...................................47
Crankshaft Gear - Remove and Install ................ 137
178 UENR4511-01
Index Section
Engine Oil Pump - Install......................................51 Removal Procedure ...........................................5

Installation Procedure ......................................51 Fuel Temperature Sensor - Remove and Install ... 147
Engine Oil Pump - Remove ..................................46 Installation Procedure .................................... 148
Removal Procedure .........................................46 Removal Procedure ....................................... 147
Engine Support (Front) - Remove and Install .........62
Installation Procedure ......................................63
Removal Procedure .........................................62 G
Engine Support (Front) - Remove and Install Gear Group (Front) - Install ..................................78
(Option 2) .........................................................64 Installation Procedure ......................................78
Installation Procedure ......................................65 Gear Group (Front) - Remove ..............................77
Removal Procedure .........................................64 Removal Procedure .........................................77
Exhaust Elbow - Remove and Install.....................35
Installation Procedures.....................................35
Removal Procedure .........................................35 H
Exhaust Manifold - Remove and Install .................32
Installation Procedure ......................................33 Housing (Front) - Install .......................................81
Removal Procedure .........................................32 Installation Procedure ......................................81
Housing (Front) - Remove....................................80
Removal Procedure .........................................80
F
Fan - Remove and Install ................................... 159 I
Removal Procedure ....................................... 159 Idler Pulley - Remove and Install (Grooved Idler
Fan Drive - Assemble ........................................ 162 Pulley) ............................................................ 157
Assembly Procedure ...................................... 162 Installation Procedure .................................... 158
Fan Drive - Disassemble.................................... 161 Removal Procedure ....................................... 157
Disassembly Procedure ................................. 161 Important Safety Information ..................................2
Fan Drive - Install .............................................. 164 Injection Actuation Pressure Sensor - Remove
Installation Procedure .................................... 164 and Install ....................................................... 148
Fan Drive - Remove .......................................... 160 Installation Procedure .................................... 149
Flywheel - Install .................................................66 Inlet and Exhaust Valve Guides - Remove and
Installation Procedure ......................................66 Install ...............................................................40
Flywheel - Remove..............................................65 Installation Procedure ......................................40
Flywheel Housing - Remove and Install.................69 Inlet and Exhaust Valve Springs - Remove and
Installation Procedure ......................................70 Install ...............................................................36
Removal Procedure .........................................69 Installation Procedure ......................................37
Front Cover - Install .............................................76 Removal Procedure .........................................36
Installation Procedure ......................................76 Inlet and Exhaust Valves - Remove and Install.......38
Front Cover - Remove .........................................75 Installation Procedure ......................................39
Fuel Filter Base - Assemble .................................10 Inlet Manifold Pressure Sensor - Remove and
Assembly Procedure ........................................10 Install ............................................................. 152
Fuel Filter Base - Assemble (Option 2).................. 11 Installation Procedure .................................... 153
Assembly Procedure ........................................ 11 Removal Procedure ....................................... 152
Fuel Filter Base - Disassemble ...............................8 Inlet Manifold Temperature Sensor - Remove
Disassembly Procedure .....................................8 and Install ....................................................... 151
Fuel Filter Base - Disassemble (Option 2) ...............9 Installation Procedure .................................... 152
Disassembly Procedure .....................................9 Removal Procedure ....................................... 151
Fuel Filter Base - Install ....................................... 11
Installation Procedure ...................................... 11
Fuel Filter Base - Install (Option 2)........................13 L
Installation Procedure ......................................13 Lifter Group - Remove and Install ....................... 107
Fuel Filter Base - Remove......................................6 Installation Procedure .................................... 107
Removal Procedure ...........................................6 Removal Procedure ....................................... 107
Fuel Filter Base - Remove (Option 2) ......................7
Removal Procedure ...........................................7
Fuel Pressure Sensor - Remove and Install......... 145 P
Removal Procedure ....................................... 145 Piston Cooling Jets - Remove and Install ............ 120
Fuel Pressure Sensor - Remove and Install Installation Procedure .................................... 120
(Option 2) ....................................................... 146 Removal Procedure ....................................... 120
Installation Procedure .................................... 147 Pistons and Connecting Rods - Assemble........... 123
Removal Procedure ....................................... 146 Assembly Procedure ...................................... 123
Fuel Priming Pump - Remove and Install.................5 Pistons and Connecting Rods - Disassemble ...... 122
Installation Procedure ........................................5 Disassembly Procedure ................................. 122
UENR4511-01 179
Index Section
Pistons and Connecting Rods - Install................. 124 Assembly Procedure ........................................54

Installation Procedure .................................... 124 Water Pump - Disassemble..................................53
Pistons and Connecting Rods - Remove ............. 121 Disassembly Procedure ...................................53
Removal Procedure ....................................... 121 Water Pump - Install ............................................56
Water Pump - Remove ........................................52
R Removal Procedure ................................... 52–53
Refrigerant Compressor - Remove and Install ..... 139 Water Separator and Fuel Filter (Primary) -
Installation Procedure .................................... 141 Remove and Install ............................................14
Removal Procedure ....................................... 139 Installation Procedure ......................................15
Rocker Arm - Assemble .......................................95 Removal Procedure .........................................14
Assembly Procedure ........................................95 Water Temperature Regulator - Remove and
Rocker Arm - Disassemble...................................94 Install ...............................................................57
Disassembly Procedure ...................................94 Installation Procedure ......................................58
Rocker Arm and Shaft - Install ..............................96 Removal Procedure .........................................57
Rocker Arm and Shaft - Remove ..........................93
S
Speed/Timing Sensor - Remove and Install ......... 150
T
Table of Contents ..................................................3
Turbocharger - Install ..........................................30
Turbocharger - Remove.......................................29
U
Unit Injector Hydraulic Pump - Install ....................25
Unit Injector Hydraulic Pump - Remove.................24
V
V-Belts - Remove and Install (Charging
Alternator Drive Belts)...................................... 154
V-Belts - Remove and Install (Water Pump
Drive Belt)....................................................... 155
Valve Mechanism Cover - Remove and Install .......88
Valve Mechanism Cover Base - Remove and
Install ...............................................................91
Vibration Damper and Pulley - Remove and
Install ...............................................................72
W
Water Pump - Assemble ......................................54
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UENR4511-01 (en-us)

Disassembly and Assembly

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Valve Mechanism Cover Base - Remove and

Alternator - Remove and Install (High Mounted

Disassembly and 3. Remove gasket (3).

Assembly Section Installation Procedure

1. Turn the fuel supply to the OFF position. Illustration 2 g03778539

1. Position a new gasket (3) on fuel filter base (4).

Note: Ensure correct orientation of the joint.

2. Position fuel priming pump (1) on fuel filter base

2. Remove bolts (2). Remove fuel priming pump (1)

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

Fuel Filter Base - Remove

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

7. If necessary, follow Step 7.a through Step 7.b in

b. Remove bolts (14) and washers (13). Remove Typical example

7. If necessary, follow Step 7.a through Step 7.b to

a. If necessary, remove the assembly of primary Illustration 7 g03779438

8. Remove adapter (8) from fuel filter base assembly

Fuel Filter Base - Disassemble

NOTICE Illustration 8 g06015010

2. Install a new O-ring seal (18), and a new O-ring

End By: 3. Install a new O-ring seal (4) to elbow connection

Fuel Filter Base - Install

2. If necessary, follow Step 2.a through Step 2.b in

a. Position bracket (12) onto the cylinder block. Illustration 12 g03778700

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

Fuel Filter Base - Install

3. Position fuel filter base (7) and install washers (2)

1. Ensure that all components of the fuel filter base

a. Position bracket (12) onto the cylinder block.

b. If necessary, install the assembly of primary

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

Water Separator and Fuel

Contaminants may cause rapid wear and shortened Typical example

7. If necessary, follow Step 7.a through Step 6.e in

2. If necessary, follow Step 2 through Step 4 in order

b. Install a new O-ring seal (6) to adaptor (7).

c. Install a new O-ring seal (9) to plug (8). Install

d. Install plug (14) to the assembly of primary

e. Install a new O-ring seal (10) O-ring seal (13),

Electronic Unit Injector -

Tool Part Number Part Description Qty

Fuel Injector Installer and

Illustration 21 g03775306 Illustration 22 g03774344

1. Remove plug (1) from the rear of the cylinder

2. Use a suitable tool to disconnect harness

Note: Do not use a wire brush on the tip of the

GE50028 Vacuum Pump 1

GE50046 Bottle Assembly 1

K GE50023 Tapered Brush 1

L - Vacuum Gun Kit 1

1. Evacuate as much fuel and oil as possible from the

Place a 38 mm (1.5 inch) square piece of Scotch