Disassembly and

Assembly

2206-E13 Industrial Engine

Engine Oil Pump - Remove

Removal Procedure

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

g01385694

Illustration 66

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.  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 - Change”.

g01385651

Illustration 67

4.  Remove bolts (7) and disconnect tube assembly

(5) from engine oil pump (11). Remove O-ring seal

(8) (not shown) from tube assembly (5).

5.  Remove bolts (9) and disconnect tube assembly

(6) from engine oil pump (11).

6.  Remove bolts (10).

7.  Remove bolts (12).

8.  Remove engine oil pump (11).

g01385650

Illustration 65

2.  Loosen the hose clamps and disconnect hose (4)

from connection (2).

3.  Remove bolts (1). Remove connection (2) from

the water pump. Remove O-ring  seal (3) (not

shown) from the water pump.

g01386064

Illustration 68

This document has been printed from SPI². Not for Resale

 

KENR6906

33

Disassembly and  Assembly Section

9.  Remove O-ring seals (13) and (14) from engine

oil pump (11).

g01391548

Illustration 69

10. Remove O-ring seals (15) and (16) from engine

oil pump (11).

g01395753

Illustration 70

i02754790

1.  Remove manifold (4).

Engine Oil Pump - Disassemble

2.  Remove tube assemblies (5) and (9).

3.  Remove the O-ring seals from tube assemblies

(5) and (9).

Disassembly Procedure

4.  Use Tooling (A) in order to remove gear (2).

5.  Remove bolts (10).

Table 15

Required Tools

Part

6.  Remove cover (6) from engine oil pump (1).

Tool

Number

Part Description

Qty

A

-

Puller

1

7.  Remove shaft assembly (3) and shaft assembly

(8) from engine oil pump (1).

Start By:

8.  Remove oil seal (7).

a.  Remove the engine  oil pump. Refer  to

Disassembly and Assembly, “Engine Oil Pump

- Remove”.

i02754791

Engine Oil Pump - Assemble

Assembly Procedure

Table 16

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART

Rubber Grease

A

21820221

1

1.  Ensure that all components of the engine oil pump

are clean and free from wear or damage. Refer

to the Specifications, “Engine Oil Pump” for more

information.

This document has been printed from SPI². Not for Resale

 

34

KENR6906

Disassembly and  Assembly Section

8.  Install new O-ring seals to tube assemblies (5) and

(9). Lubricate the O-ring seals with Tooling (A).

9.  Install tube assemblies (5) and (9) to cover (6).

10. Install manifold (4) onto tube assemblies (5) and

(9).

End By:

a.  Install the engine oil pump. Refer to Disassembly

and Assembly, “Engine Oil Pump - Install”.

i02754792

Engine Oil Pump - Install

Installation Procedure

g01395753

Illustration 71

Table 17

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART

Rubber Grease

A

218200221

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01146945

Illustration 72

2.  Lubricate shaft assemblies (3) and (8) with clean

engine oil. Install the shaft assemblies into engine

oil pump (1).

3.  Install a new oil seal (7) to engine oil pump (1).

4.  Position cover (6) onto engine oil pump (1) and

install bolts (10).

5.  Tighten bolts (10) to a torque of 28 N·m (21 lb ft).

g01391548

Illustration 73

Always  wear  protective  gloves  when  handling

parts that have been heated.

6.  Heat gear (2) to a temperature of 316 °C (600 °F).

7.  Install gear (2) to shaft assembly (3).  Ensure

that Dimension  (X) is 29.40  ± 0.50 mm

(1.158 ± 0.020 inch).

This document has been printed from SPI². Not for Resale

 

KENR6906

35

Disassembly and  Assembly Section

6.  Install new O-ring seal (8) (not shown) to tube

assembly (5). Connect the  tube assembly to

engine oil pump (11) and install bolts (7).

7.  Tighten bolts (7) and bolt (9) to a torque of 28 N·m

(21 lb ft).

g01386064

Illustration 74

1.  Install new O-ring seal (14) to engine oil pump

(11). Lubricate the O-ring seal with Tooling (A).

2.  Install new O-ring seals (13), (15) and (16)  to

engine oil pump (11).

g01385650

Illustration 77

8.  Install a new O-ring seal (3) (not shown) to the

water pump. position connection (2) and install

bolts (1). Tighten the bolts to a torque of 28 N·m

(21 lb ft).

9.  Connect hose (4) to connection (2). Tighten the

hose clamps securely.

10. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant

- Change”.

i02754793

g01385651

Illustration 75

Water Pump - Remove

Removal Procedure

Start By:

a.  Remove the front plate and the support bracket.

Refer to Disassembly and Assembly, “Front Plate

- Remove”

NOTICE

Keep all parts clean from contaminants.

g01385694

Illustration 76

Contaminants may cause  rapid wear and  shortened

component life.

3.  Position engine oil pump (11) and install bolts (12)

finger tight.

4.  Install bolts (10). Tighten bolts (10) and (12) to a

torque of 28 N·m (21 lb ft).

5.  Connect tube assembly (6) to engine oil pump

(11) and install bolts (9).

This document has been printed from SPI². Not for Resale

 

36

KENR6906

Disassembly and  Assembly Section

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations 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 - Change”.

g01384522

Illustration 79

4.  Loosen the hose clamps and disconnect hose (9).

g01391599

Illustration 78

5.   Remove bolts (11) and remove connection (10).

Remove O-ring seal (4) (not shown) from water

pump (12).

2.  Remove bolts (1). Remove water temperature

regulator housing (2) as a unit. Remove the O-ring

seal from the water temperature regulator housing.

6.  Loosen the hose clamps and slide hose (5) toward

connection (6). Remove bolts (7) and remove the

connection from water pump (12). Remove the

O-ring seal from the connection.

3.  Remove tube assembly (3). Remove the O-ring

seals from the tube assembly.

7.  Remove bolts (8).

8.  Remove water pump (12).

g01391623

Illustration 80

This document has been printed from SPI². Not for Resale

 

KENR6906

37

Disassembly and  Assembly Section

9.  Remove O-ring seal (13) from water pump (12).

i02754794

Water Pump - Install

Installation Procedure

Table 18

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART

Rubber Grease

A

218200221

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Ensure that all mating surfaces are clean and free

from damage.

g01384522

Illustration 82

3.  Position water pump (12) on the engine and install

bolts (8). Tighten the bolts to a torque of 55 N·m

(41 lb ft).

4.  Install a new O-ring seal to connection (6). Loosely

assemble hose (5) and the hose clamps to the

connection.

5.  Position connection (6) on water pump (12) and

install bolts (7). Tighten the bolts to a  torque of

28 N·m (21 lb ft).

6.  Connect hose (5) to the oil cooler. Tighten the

hose clamps securely.

g01391623

Illustration 81

2.  Install a new O-ring seal (13) to water pump (12).

Lubricate the O-ring seal with Tooling (A).

7.  Install a new O-ring seal (4) (not shown) to water

pump (12). Position connection (10) on the water

pump and install bolts (11). Tighten the bolts to a

torque of 28 N·m (21 lb ft).

8.  Connect hose (9) and tighten the hose clamps

securely.

This document has been printed from SPI². Not for Resale

 

38

KENR6906

Disassembly and  Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

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 - Change”.

g01391599

Illustration 83

9.  Install new O-ring seals to tube assembly (3).

Lubricate the O-ring seals with Tooling (A).

10. Install tube assembly (3) to the water pump.

11. Install a new O-ring seal to water temperature

regulator housing (2). Align the water temperature

regulator housing with tube assembly  (3) and

install the water temperature regulator housing.

12. Install bolts (1). Tighten the bolts to a torque of

Illustration 84

g01390192

28 N·m (21 lb ft).

Typical example

13. Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant

- Change”.

2.  Remove bolts (1).

3.  Remove water temperature regulator housing (2)

and tube assembly (3).

End By:

4.  Remove the O-ring seals from tube assembly (3).

a.  Install the front plate and the support bracket.

Refer to Disassembly and Assembly, “Front Plate

- Install”.

i02754796

Water Temperature Regulator

Housing - Remove and Install

Removal Procedure

NOTICE

g01390160

Illustration 85

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

5.  Remove O-ring seal (7) from water temperature

regulator housing (2).

6.  Remove water temperature regulator (6).

7.  If necessary, remove lip seal  (5) from water

temperature regulator housing (2).

Dispose of all fluids according to local regulations and

mandates.

This document has been printed from SPI². Not for Resale

 

KENR6906

39

Disassembly and  Assembly Section

3.  Ensure that valve (9) is clean  and free from

restriction. If necessary, follow Steps 3.a and 3.b

in order to install the valve to housing manifold (8).

a.  Install a new O-ring seal to valve (9). Apply

Tooling (B) to the O-ring seal.

b. Install valve (9) to housing manifold (8).

g01390109

Illustration 86

8.  If necessary, remove valve (9) from  housing

manifold (8). Remove the O-ring seal from  the

valve.

Installation Procedure

g01390160

Illustration 88

Table 19

Required Tools

4.  If necessary, install a new lip seal (5) to  water

temperature regulator housing (2). Use Tooling

(A) to install the lip seal.

Tool

Part Number

Part Description

Qty

A

27610309

Seal Installer

1

5.  Install a new O-ring seal (7) to water temperature

regulator housing (2).

POWERPART

Rubber Grease

B

21820221

1

6.  Install water temperature regulator (6) to water

temperature regulator housing (2).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Ensure that the mating surfaces of the  water

temperature regulator housing and the housing

manifold are clean and free from damage.

2.  Check the water temperature regulator for correct

operation. Refer to Systems Operation, Testing

and Adjusting, “Water Temperature Regulator -

Test” for the correct procedure.

g01390192

Illustration 89

Typical example

7.  Install new O-ring seals to tube assembly (3).

Apply Tooling (B) to the O-ring seals. Install the

tube assembly to the water pump.

8.  Position water temperature regulator housing (2)

and install bolts (1). Tighten the bolts to a torque

of 28 N·m (21 lb ft).

9.  Fill the cooling system. Refer to Operation and

Maintenance Manual, “Cooling System Coolant

- Change”.

g01390109

Illustration 87

This document has been printed from SPI². Not for Resale

 

40

KENR6906

Disassembly and  Assembly Section

i02754798

Installation Procedure

Engine Support  (Front) -

Remove and Install

Table 21

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

(M12 by 100mm)

A

-

2

Removal Procedure

Table 20

1.  Ensure that the front of the engine is supported.

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

(M12 by 100mm)

A

-

2

Start By:

a.  Remove the vibration damper and the crankshaft

pulley. Refer to Disassembly  and Assembly,

“Vibration Damper and Pulley -  Remove and

Install”.

1.  Support the front of the engine.

g01380895

Illustration 91

2.  Install Tooling (A) to positions (X) on the cylinder

block.

3.  Install a suitable  lifting device to  engine

support (2). The weight of engine support (2) is

approximately 25 kg (55 lb).

4.  Use the lifting device to align engine support (2)

with Tooling (A). Install the engine support to the

cylinder block.

5.  Install bolts (1) finger tight. Remove Tooling (A)

and install the remaining bolts. Tighten bolts to a

torque of 100 N·m (74 lb ft).

g01380895

Illustration 90

2.  Attach a suitable  lifting device to engine

support (2). The weight of the engine support is

approximately 25 kg (55 lb).

End By:

a.  Install the vibration damper and the crankshaft

pulley. Refer to Disassembly  and Assembly,

“Vibration Damper and Pulley  - Remove and

Install”.

3.  Remove bolts (1) from positions (X) and install

Tooling (A) to positions (X). Remove the remaining

bolts (1).

4.  Use the lifting device to remove engine support

(2) from the cylinder block.

5.  Remove Tooling (A).

This document has been printed from SPI². Not for Resale

 

KENR6906

41

Disassembly and  Assembly Section

i02754801

5.  Remove the remaining bolts (1). Use the lifting

device in order to remove flywheel (2).

Flywheel - Remove

Removal Procedure

Table 22

Required Tools

Part

Tool

Number

Part Description

Qty

Guide  Stud

M16 by 120mm

A

-

2

Start By:

g01389418

Illustration 93

Typical example

a.  Remove the electric starting motor. Refer  to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

6.  Inspect flywheel (2) and ring gear (3) for wear or

damage. Replace any components that are worn

or damaged.

NOTICE

Keep all parts clean from contaminants.

7.  To remove the ring gear, follow Steps 7.a and 7.b.

a.  Place flywheel (2) on a suitable support.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Identify the orientation of the teeth on the ring

gear.

b. Use a hammer and a punch in order to remove

ring gear (3) from flywheel (2).

i02754802

Flywheel - Install

Installation Procedure

Table 23

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

M16 by 120mm

A

-

2

g01383279

POWERPART

Threadlock and Nutlock

Illustration 92

B

21820117

1

Typical example

1.  Attach a suitable lifting device to flywheel (2).

Support the weight of the flywheel. The weight of

the flywheel is approximately 50 kg (110 lb).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

2.  Use a suitable tool to lock flywheel (2). Loosen

bolts (1).

3.  Remove two bolts (1) from positions (X).

4.  Install Tooling (A) to positions (X).

This document has been printed from SPI². Not for Resale

 

42

KENR6906

Disassembly and  Assembly Section

g01389418

Illustration 94

Always  wear  protective  gloves  when  handling

parts that have been heated.

g01389447

Illustration 95

1.  If the ring gear was removed, follow Steps 1.a

through 1.c in order to install a new ring gear to

the flywheel.

Typical example

3.  Install Tooling (A) to  positions (X) on  the

crankshaft.

a.  Identify the orientation of the teeth on new ring

gear (3).

4.  Install a suitable lifting device to flywheel (2). The

weight of the flywheel is  approximately 50 kg

(110 lb).

Note: The chamfered side of the ring gear teeth must

face toward the starting motor when the flywheel is

installed. This will ensure the correct engagement of

the starting motor.

5.  Use the lifting device in order to position flywheel

(2) onto Tooling (A). Ensure that Marks (Y) on the

flywheel and on the crankshaft are aligned.

b. Heat ring  gear (3) in an oven to a maximum

temperature of 316  °C (600 °F) prior  to

installation.

6.  Apply Tooling (B) to the threads of bolts (1).

7.  Install bolts (1). Remove Tooling  (A). Install

remaining bolts (1).

Note: Do not use a torch to heat the ring gear.

8.  Use a suitable tool to prevent the flywheel from

rotating. Tighten bolts (1) to a torque of 300 N·m

(221 lb ft).

c.  Ensure that the orientation of ring gear (3) is

correct and quickly install the ring gear onto

flywheel (2).

9.  Remove the lifting device from flywheel (2).

2.  Inspect the crankshaft rear seal for leaks. If there

are any oil leaks, replace the crankshaft rear seal.

Refer to Disassembly and Assembly, “Crankshaft

Rear Seal - Remove”.

10. Check the runout of the  flywheel. Refer to

Systems Operations, Testing and  Adjusting,

“Flywheel - Inspect”.

End By:

a.  Install the electric starting  motor. Refer to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

This document has been printed from SPI². Not for Resale

 

KENR6906

43

Disassembly and  Assembly Section

i02754803

i02754805

Crankshaft Rear Seal - Remove

Crankshaft Rear Seal - Install

Removal Procedure

Installation Procedure

Start By:

Table 24

Required Tools

Part

a.  Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.

Tool

Number

Part Description

Qty

POWERPART

Threadlock and Nutlock

NOTICE

Keep all parts clean from contaminants.

A

21820117

1

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Ensure that the crankshaft flange and the housing

for the crankshaft rear seal is clean, dry and free

from damage. It is possible to reclaim a crankshaft

flange that has a worn seal surface, or a damaged

seal surface by installing a wear sleeve. Refer to

Disassembly and Assembly, “Crankshaft Wear

Sleeve (Rear) - Remove and  Install” for more

information.

g01389635

Illustration 96

1.  Remove bolts (1) and (3).

2.  Remove crankshaft rear seal (2).

3.  Remove the O-ring seal from crankshaft rear seal

(2).

g01389636

Illustration 97

This document has been printed from SPI². Not for Resale

 

44

KENR6906

Disassembly and  Assembly Section

i02807660

Crankshaft Wear Sleeve (Rear)

- Remove and Install

Removal Procedure

Start By:

a.  Remove the crankshaft rear  seal. Refer to

Disassembly and Assembly, “Crankshaft Rear

Seal - Remove”.

g01395750

Illustration 98

Tightening sequence for the crankshaft rear seal

NOTICE

Keep all parts clean from contaminants.

2.  Install a new O-ring seal to crankshaft rear seal

(2). A new crankshaft rear seal is supplied with a

plastic sleeve. Ensure that the plastic sleeve is

squarely installed within the crankshaft rear seal.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves

are not original equipment.

Note: The plastic sleeve  is included in order to

protect the lip of the seal as the seal is pushed over

the crankshaft flange.

1.  Use a sharp tool to score a deep line across the

crankshaft wear sleeve.

Note: Do not lubricate the crankshaft rear seal or

the crankshaft flange. The crankshaft rear seal

must be installed dry.

Note: Take care to avoid damaging the crankshaft.

3.  Align the plastic sleeve with the crankshaft flange.

Ensure that the plastic sleeve is engaged onto the

crankshaft flange. Push new crankshaft rear seal

(2) squarely onto the crankshaft flange.

2.  Insert a thin blade between the crankshaft wear

sleeve and the crankshaft below the scored line.

The crankshaft wear sleeve will separate along

the line.

During this process, the plastic  sleeve will be

forced out of the crankshaft rear seal. Discard the

plastic sleeve.

3.  Remove the crankshaft wear sleeve from the

crankshaft.

Installation Procedure

4.  Apply Tooling (A) to the threads of bolts (3). Install

bolts (1) and (3). Tighten the bolts to a torque of

12 N·m (105 lb in) in the numerical sequence that

is shown in Illustration 98.

Table 25

Required Tools

Tool

Part Number

21820518

CVT0017

-

Part Description

Qty

1

End By:

POWERPART

Liquid Gasket

A

a.  Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.

Installer

1

B

Bolt

(M16 by 30 mm)

3

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

This document has been printed from SPI². Not for Resale

 

KENR6906

45

Disassembly and  Assembly Section

Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves

are not original equipment.

Start By:

a.  Remove the electric starting motor. Refer  to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

1.  Ensure that the crankshaft is thoroughly clean and

dry. Remove any areas of raised damage.

b. Remove the flywheel. Refer  to Disassembly and

2.  Apply a small continuous bead of Tooling (A) to the

inner surface of the crankshaft wear sleeve. Apply

the bead of Tooling (A) 5.00 mm (0.2 inch) from

the chamfered end of the crankshaft wear sleeve.

Assembly, “Flywheel - Remove”.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

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.

g01401603

Illustration 99

Sectional view of  the crankshaft, the wear sleeve  and the

installation tool

1.  Support the rear of the engine.

3.  Align crankshaft wear sleeve (1) with crankshaft

(2). Install Tooling (B) to crankshaft (2). Evenly

tighten the bolts of Tooling (B) in order to install

the crankshaft wear sleeve.

4.  Remove Tooling (B).

End By:

a.  Install a new crankshaft rear  seal. Refer to

Disassembly and Assembly, “Crankshaft Rear

Seal - Install”.

i02754806

Flywheel Housing - Remove

and Install

g01383281

Illustration 100

Removal Procedure

2.  Attach a suitable lifting  device to flywheel

housing (2). The weight of the flywheel housing is

approximately 25 kg (55 lb).

Table 26

Required Tools

Tool

Part Number

Part Description

Qty

3.  Remove bolts (1) from positions (X). Install Tooling

(A) to positions (X).

Guide  Stud

(M14 by 100mm)

A

-

2

4.  Remove the remaining bolts (1). Use the lifting

device to remove flywheel housing (2) from the

cylinder block.

This document has been printed from SPI². Not for Resale

 

46

KENR6906

Disassembly and  Assembly Section

Note: It is not necessary to remove the dowels in the

cylinder block that locate the flywheel housing.

g01389649

Illustration 101

5.  Remove O-ring seal (3) from housing (4).

Installation Procedure

g01383281

Illustration 103

Table 27

3.  Apply Tooling (B) to the rear face of the cylinder

block.

Required Tools

Part

Note: The flywheel housing must be installed within

ten minutes of applying Tooling (B).

Tool

Part Description

Qty

Number

Guide  Stud

(M14 by 100mm)

A

B

-

2

1

4.  Install Tooling (A) to positions (X) in the cylinder

block.

CH10879

Sealant

5.  Attach a suitable lifting  device to flywheel

housing (2). The weight of the flywheel housing is

approximately 25 kg (55 lb).

1.  Ensure that the mating surfaces of the flywheel

housing and the cylinder block are clean and free

from damage.

6.  Use the lifting device to align flywheel housing (2)

with Tooling (A).

7.  Install flywheel housing (2) to the cylinder block.

8.  Install bolts (1). Remove Tooling (A). Install the

remaining bolts. Tighten the bolts to a torque of

160 N·m (118 lb ft).

End By:

a.  Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.

b. Install  the electric starting motor.  Refer to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

g01389649

Illustration 102

2.  Install a new O-ring seal (3) to housing (4).

This document has been printed from SPI². Not for Resale

 

KENR6906

47

Disassembly and  Assembly Section

i02754807

Vibration Damper and Pulley -

Remove and Install

Removal Procedure

Table 28

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

(M16 by 120mm)

A

-

2

g01380897

Illustration 105

2.  Remove the V-belts from crankshaft pulley (4).

Temporarily secure the V-belts in a position that

is clear of vibration damper (3).

Start By:

a.  Remove the fan. Refer to  Disassembly and

Assembly, “Fan - Remove and Install”.

3.  Remove two bolts (6). Install Tooling (A).

4.  Remove the remaining bolts (6) and spacer (5).

5.  Remove crankshaft pulley (4).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

6.  Install a suitable lifting device to vibration damper

(3). The weight  of the vibration damper  is

approximately 36 kg (79 lb). Make a temporary

mark in order to show the front of  the vibration

damper for installation.

7.  Use the lifting device to remove vibration damper

(3) from the crankshaft.

8.  Remove Tooling (A) from the crankshaft.

Installation Procedure

Table 29

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

A

-

2

(M16 by 120mm)

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Thoroughly inspect  the viscous  damper for signs  of

leakage  or for  signs  of a  dented  (damaged) case.

Either of  these  conditions can  cause the  weight  to

make contact  with the case. This  can affect the  vis-

cous damper’s operation.

g01417120

Illustration 104

1.  Loosen nut (1) that locks the position of the belt

tightener. Rotate bolt (2) in order to release the

tension on the V-belts.

This document has been printed from SPI². Not for Resale

 

48

KENR6906

Disassembly and  Assembly Section

1.  Inspect the components for damage. Replace any

components that are damaged.

2.  Inspect the crankshaft front seal for  leaks. If

necessary, replace the crankshaft front seal. Refer

to Disassembly and Assembly, “Crankshaft Front

Seal - Remove”.

3.  Install Tooling (A) to the crankshaft.

g01380897

Illustration 106

4.  Install a suitable lifting device to vibration damper

(3). The weight  of the vibration damper  is

approximately 36 kg (79 lb).

g01417120

Illustration 107

5.  Use the lifting device to align vibration damper (3)

with Tooling (A). Install the vibration damper to the

crankshaft.

9.   Position the V-belts on the crankshaft pulley and

the pulley of the belt tightener.

10. Rotate bolt (2) in order to adjust the tension of

the V-belts. Refer to Operation and Maintenance

Manual, “Belts - Inspect/Adjust/Replace”.

Note: Ensure correct orientation of  the vibration

damper.

6.  Remove the lifting device.

11. Tighten nut (1) in order to lock the position of the

belt tightener.

7.  Install crankshaft pulley (4) and spacer (5).

End By:

8.  Install bolts (6). Remove Tooling (A) and install the

remaining bolts (6). Tighten the bolts to a torque

of 240 N·m (177 lb ft).

a.  Install the fan. Refer  to Disassembly and

Assembly, “Fan - Remove and Install”.

i02754808

Crankshaft Front  Seal -

Remove

Removal Procedure

Start By:

a.  Remove the vibration damper and the crankshaft

pulley. Refer to Disassembly  and Assembly,

“Vibration Damper and Pulley  - Remove and

Install”.

This document has been printed from SPI². Not for Resale

 

KENR6906

49

Disassembly and  Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01383288

Illustration 109

g01383288

Illustration 108

1.  Remove nuts (1).

2.  Remove crankshaft front seal (2).

3.  Remove the O-ring seal from crankshaft front seal

(2).

g01132632

Illustration 110

i02754809

Tightening sequence for the crankshaft front seal

Crankshaft Front Seal - Install

,

2.  Install a new O-ring seal to crankshaft front seal

(2). A new crankshaft front seal is supplied with a

plastic sleeve. Ensure that the plastic sleeve is

squarely installed within the crankshaft front seal.

Installation Procedure

Note: The plastic sleeve is  included in order to

protect the lip of the seal as the seal is pushed over

the crankshaft flange.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Do not lubricate the crankshaft front seal or

the crankshaft flange. The crankshaft front seal

must be installed dry.

1.  Ensure that the crankshaft flange and the front

cover are clean, dry and free from damage.

3.  Align the plastic sleeve with the crankshaft flange.

Ensure that the plastic sleeve is engaged onto the

crankshaft flange. Push new crankshaft front seal

(2) squarely onto the crankshaft flange.

During this process, the plastic  sleeve will be

forced out of the crankshaft front seal. Discard the

plastic sleeve.

4.  Install nuts (1). Tighten the nuts to a torque  of

12 N·m (105 lb in) in the numerical sequence that

is shown in Illustration 110.

This document has been printed from SPI². Not for Resale

 

50

KENR6906

Disassembly and  Assembly Section

End By:

Installation Procedure

a.  Install the vibration damper and the crankshaft

pulley. Refer to Disassembly  and Assembly,

“Vibration Damper and Pulley -  Remove and

Install”.

Table 31

Required Tools

Tool

Part Number

21820518

CVT0018

-

Part Description

Qty

1

POWERPART

Liquid Gasket

A

i02810672

Installer

1

Crankshaft Wear Sleeve (Front)

- Remove and Install

B

Bolt

(M16 by 30 mm)

3

NOTICE

Keep all parts clean from contaminants.

Removal Procedure

Contaminants may cause  rapid wear and  shortened

component life.

Table 30

Required Tools

Part

Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves

are not original equipment.

Tool

Number

Part Description

Qty

A

-

Puller

1

1.  Ensure that the crankshaft is thoroughly clean and

dry. Remove any areas of raised damage.

Start By:

a.  Remove the crankshaft front seal.  Refer to

Disassembly and Assembly, “Crankshaft Front

Seal - Remove”.

2.  Apply a small continuous bead of Tooling (A) to the

inner surface of the crankshaft wear sleeve. Apply

the bead of Tooling (A) 5.00 mm (0.2 inch) from

the chamfered end of the crankshaft wear sleeve.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves

are not original equipment.

1.  Use a sharp tool to score a deep line across the

crankshaft wear sleeve.

Note: Take care to avoid damaging the crankshaft.

g01402019

Illustration 111

2.  Insert a thin blade between the crankshaft wear

sleeve and the crankshaft below the scored line.

The crankshaft wear sleeve will separate along

the line.

Sectional view of  the crankshaft, the wear sleeve  and the

installation tool

3.  Align crankshaft wear sleeve (1) with crankshaft

(2). Install Tooling (B) to crankshaft (2). Evenly

tighten the bolts of Tooling (B) in order to install

the crankshaft wear sleeve.

3.  Remove the crankshaft wear sleeve from the

crankshaft.

4.  Remove Tooling (B).

This document has been printed from SPI². Not for Resale

 

KENR6906

51

Disassembly and  Assembly Section

End By:

a.  Install a new crankshaft front  seal. Refer to

Disassembly and Assembly, “Crankshaft Front

Seal - Install”.

i02754810

Front Cover - Remove

Removal Procedure

g01392333

Start By:

Illustration 113

Typical example

a.  Remove the front plate. Refer to Disassembly and

Assembly, “Front Plate - Remove”.

2.  Remove bolts (3) and (4).

b. Remove  the crankshaft front seal. Refer  to

Disassembly and Assembly, “Crankshaft Front

Seal - Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

g01395833

Illustration 114

3.  Remove bolts (5), fasteners (6) and bolt (7).

4.  Remove front cover (8) and joint (9) (not shown).

i02754811

Front Cover - Install

Installation Procedure

Table 32

g01395819

Illustration 112

Required Tools

Part

1.  Remove bolts (1) and plate (2). Remove  the

O-ring seal from the front housing.

Tool

Number

Part Description

Qty

POWERPART

Threadlock and Nutlock

A

21820117

1

This document has been printed from SPI². Not for Resale

 

52

KENR6906

Disassembly and  Assembly Section

5.  Install bolts (3). Tighten the bolts to a torque of

55 N·m (41 lb ft).

NOTICE

Keep all parts clean from contaminants.

6.  Apply Tooling (A) to bolt (7).

7.  Install bolts (4), (5) and (7).

Contaminants may cause  rapid wear and  shortened

component life.

8.  Tighten bolts (4), (5) and (7) to a torque of 28 N·m

(21 lb ft).

1.  Ensure that the front cover and the mating surface

of the front housing  are clean and free from

damage.

g01395819

Illustration 117

9.  Install a new O-ring seal to the  front housing.

Position plate (2) and install bolts (1). Tighten the

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

End By:

a.  Install a new crankshaft front  seal. Refer to

Disassembly and Assembly, “Crankshaft Front

Seal - Install”.

g01395833

Illustration 115

b. Install the  front plate. Refer to Disassembly and

Assembly, “Front Plate - Install”.

i02754812

Gear Group (Front) - Remove

Removal Procedure

Table 33

g01392333

Illustration 116

Required Tools

Part

Typical example

2.  Align a new joint (9) (not shown) with the dowels

in the front housing. Install the joint.

Tool

Number

CH11148

27610286

CVT0015

Part Description

Crankshaft Turning Tool

Timing Pin (Crankshaft)

Adapter

Qty

1

A

3.  Align front cover (8) with the dowels in the front

housing. Install the front cover.

1

B

1

4.  Install fasteners (6). Tighten the fasteners to a

torque of 100 N·m (74 lb ft).

This document has been printed from SPI². Not for Resale

 

KENR6906

53

Disassembly and  Assembly Section

Start By:

a.  Remove the front cover. Refer to Disassembly and

Assembly, “Front Cover - Remove”.

b. Remove  the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Use Tooling (A) in order to rotate the crankshaft so

that number one piston is at the top center position

on the compression stroke. Refer to  Systems

Operation, Testing and Adjusting, “Finding Top

Centre Position for No.1 Piston”.

g01400788

Illustration 119

2.  Install Tooling (B) to the flywheel housing. Use

Tooling (B) in order to align  the flywheel in the

correct position. Refer to Systems  Operation,

Testing and Adjusting,  “Finding Top Centre

Position for No.1 Piston”.

4.  Ensure that the timing marks on gears (3), (4) and

(5) are aligned.

g01400786

Illustration 120

g01393906

Illustration 118

5.  Follow Step 5.a through Step 5.c  in order to

remove idler gear (4).

3.  Loosen nuts (1) on all rocker arms .  Unscrew

adjusters (2) on all rocker arms until all valves are

fully closed.

a.  Remove bolt (8).

b. Carefully use a pry bar in order to remove gear

(4) and hub (10).

Note: Failure to ensure that ALL adjusters are fully

unscrewed can result in contact between the valves

and pistons.

c.  Remove hub (10) from gear (4).

6.  Follow Step 6.a through Step 6.c  in order to

remove idler gear (6).

a.  Remove bolt (7).

b. Carefully use a pry bar in order to remove gear

(6) and hub (9).

c.  Remove hub (9) from gear (6).

This document has been printed from SPI². Not for Resale

 

54

KENR6906

Disassembly and  Assembly Section

i02754815

Gear Group (Front) - Install

Installation Procedure

Table 34

Required Tools

Part

Tool

Number

CH11148

27610286

CVT0015

Part Description

Crankshaft Turning Tool

Timing Pin (Crankshaft)

Adapter

Qty

1

A

1

B

1

NOTICE

Keep all parts clean from contaminants.

g01400788

Illustration 122

Contaminants may cause  rapid wear and  shortened

component life.

4.  Follow Step 4.a through Step 4.c in order to install

idler gear (6).

1.  Ensure that number one piston is at the top center

position on the compression  stroke. Refer to

the Systems Operation, Testing and Adjusting,

“Finding Top Center Position for No. 1 Piston”.

a.  Lubricate hub (9) with clean engine oil. Slide

the hub into idler gear (6). Ensure that the word

FRONT on the idler gear is toward the front.

b. Install the assembly of idler  gear (6) and hub

(9) into the recess in the front housing. Ensure

that the oil hole in the hub is upward.

2.  Ensure that Tooling (B) is installed in the flywheel

housing. Tooling (B) is used to align the flywheel in

the correct position. Refer to Systems Operation,

Testing and Adjusting,  “Finding Top Centre

Position for No.1 Piston”.

Note: The idler gear must be tilted during installation.

c.  Install bolt (7). Tighten the bolt to a torque of

240 N·m (177 lb ft).

3.  Ensure that all of the components of the front gear

group are clean and free from wear or damage. If

necessary, replace any components that are worn

or damaged. Refer to Specifications, “Gear Group

(Front)” for more information.

5.  Follow Step 5.a through Step 5.c in order to install

idler gear (4).

a.  Lubricate hub (10) with clean engine oil. Slide

the hub into idler gear (4). Ensure that the word

FRONT on the idler gear is toward the front.

b. Align the  timing marks on idler gear (4) with

the timing marks on camshaft gear (3) and the

timing marks on crankshaft gear (5). Refer to

the Illustration 122. Install the assembly of idler

gear (4) and hub (10) into the  recess in the

front housing. Ensure that the oil hole in the

hub is upward.

c.  Install bolt (8). Tighten the bolt to a torque of

460 N·m (340 lb ft).

g01400786

Illustration 121

6.  Remove Tooling (B).

7.  Lubricate each gear with clean engine oil.

This document has been printed from SPI². Not for Resale

 

KENR6906

55

Disassembly and  Assembly Section

8.  Adjust the engine valve lash. Refer to Systems

Operation, Testing and Adjusting, “Engine Valve

Lash - Inspect/Adjust”.

9.  Remove Tooling (A).

End By:

a.  Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Install”.

b. Install  the valve mechanism cover. Refer  to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and Install”.

i02754817

Housing (Front) - Remove

g01393936

Removal Procedure

Illustration 123

1.  Remove bolts (1).

Start By:

2.  Remove front housing (2).

3.  Remove joint (4).

a.  Remove the atmospheric pressure sensor. Refer

to Disassembly and Assembly, “Atmospheric

Pressure Sensor - Remove and Install”.

4.  If necessary, remove pump drive (3) from front

housing (2). Refer to Disassembly and Assembly,

“Pump Drive- Remove”.

b. Remove the  camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position

Sensor - Remove and Install”.

c.  Remove the crankshaft position sensor. Refer to

Disassembly and Assembly, “Crankshaft Position

Sensor - Remove and Install”.

i02754818

Housing (Front) - Install

d. Remove  the fuel transfer  pump. Refer to

Disassembly and Assembly, “Fuel Transfer Pump

- Remove”.

Installation Procedure

e.  Remove the engine  oil pump. Refer  to

Disassembly and Assembly, “Engine Oil Pump

- Remove”.

Table 35

Required Tools

Part

f.  Remove the water  pump. Refer to Disassembly

Tool

Number

Part Description

Qty

and Assembly, “Water Pump - Remove”.

Guide  Stud

A

-

2

(M8 by 80 mm)

NOTICE

g. Remove the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and

Install”.

Keep all parts clean from contaminants.

h. Remove the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Remove”.

Contaminants may cause  rapid wear and  shortened

component life.

i.   Remove the front  gear group. Refer  to

Disassembly and Assembly, “Gear Group (Front)

- Remove”.

1.  Clean the mating surfaces of the cylinder block

and the front housing.

j.   Remove the front engine support.  Refer to

Disassembly and Assembly, “Engine Support

(Front) - Remove and Install”.

This document has been printed from SPI². Not for Resale

 

56

KENR6906

Disassembly and  Assembly Section

8.  If necessary, install pump drive (3) to front housing

(2). Refer to Disassembly and Assembly, “Pump

Drive- Install”.

End By:

a.  Install the front engine  support. Refer to

Disassembly and Assembly, “Engine Support

(Front) - Remove and Install”.

b. Install the  engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove  and

Install”.

c.  Install the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Install”.

d. Install the front gear group. Refer to Disassembly

and Assembly, “Gear Group (Front) - Install”.

e.  Install the water pump. Refer to Disassembly and

Assembly, “Water Pump - Install”.

g01393955

Illustration 124

f.  Install the engine oil pump. Refer to Disassembly

and Assembly, “Engine Oil Pump - Install”.

2.  Install Tooling (A) to the cylinder block.

g. Install the fuel transfer pump. Refer to Disassembly

and Assembly, “Fuel Transfer Pump - Install”

h. Install the  crankshaft position sensor. Refer to

Disassembly and Assembly, “Crankshaft Position

Sensor - Remove and Install”.

i.   Install the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position

Sensor - Remove and Install”.

j.   Install the atmospheric pressure sensor. Refer

to Disassembly and Assembly, “Atmospheric

Pressure Sensor - Remove and Install”.

i02767682

Front Plate - Remove

g01393936

Illustration 125

Removal Procedure

3.  Install a new joint (4) to the cylinder block.

4.  Install front housing (2).

Start By:

Note: Ensure that  the front housing is seated

correctly on the dowels in the cylinder block.

a.  Remove the belt tightener. Refer to Disassembly

and Assembly, “Belt Tightener - Remove”.

5.  Install bolts (1).

b. Remove the fan drive. Refer to Disassembly and

Assembly, “Fan Drive - Remove”.

6.  Remove Tooling (A) and install the remaining bolts

(1).

7.  Tighten bolts (1) to a torque of 28 N·m (21 lb ft).

This document has been printed from SPI². Not for Resale

 

KENR6906

57

Disassembly and  Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01397091

Illustration 128

6.  If necessary, follow Steps 6.a and 6.b in order to

remove the support bracket.

a.  Remove bolts (6).

g01386146

Illustration 126

b. Remove support bracket (7).

i02767679

Front Plate - Install

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01397095

Illustration 127

1.  Remove bolts (3) (not shown) that secure plate (4)

to the support bracket.

2.  Remove nuts (1).

3.  Support the weight of plate (4). The weight of the

plate is approximately 25 kg (55 lb).

4.  Remove nuts (2) and remove plate (4).

5.  Remove spacer (5) from the cylinder head. Note

the routing of the wiring  harness between the

spacer and the cylinder head.

g01397091

Illustration 129

1.  If support bracket (7) was removed, position the

support bracket on the cylinder block and install

bolts (6) finger tight.

This document has been printed from SPI². Not for Resale

 

58

KENR6906

Disassembly and  Assembly Section

b. Install the belt tightener. Refer to Disassembly and

Assembly, “Belt Tightener - Install”.

i02754819

Crankcase Breather - Remove

and Install

(Closed Breather)

Removal Procedure

g01397095

Illustration 130

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

g01386146

Illustration 131

2.  Install spacer (5) to the cylinder head.

Note: Ensure the correct routing of the wiring harness

around the spacer.

3.  Position plate (4) on the studs and install nuts (1)

and (2).

4.  Tighten nuts (1) and (2) to a torque of 100 N·m

(74 lb ft).

5.  Install bolts (3) (not shown) finger tight.

6.  If support bracket (7) was removed, tighten bolts

(6) to a torque  of 55 N·m (41 lb  ft). Refer to

Illustration 129.

7.  Tighten bolts (3) (not shown) to a torque of 55 N·m

(41 lb ft).

Note: Ensure that the plate is not stressed as  the

bolts are tightened.

g01401970

Illustration 132

End By:

1.  Loosen the clamp and disconnect hose (1) from

crankcase breather (4).

a.  Install the fan drive. Refer to Disassembly and

Assembly, “Fan Drive - Install”.

2.  Loosen the clamp and disconnect hose (3) from

crankcase breather (4).

This document has been printed from SPI². Not for Resale

 

KENR6906

59

Disassembly and  Assembly Section

3.  Disconnect hose (5) from crankcase breather (4).

i02790384

Crankcase Breather - Remove

and Install

4.  Remove bolts (2) and remove crankcase breather

(4) from the mounting bracket.

(Open Breather)

5.  If necessary, disassemble crankcase breather

(4). Refer to Operation and Maintenance Manual,

“Engine Crankcase Breather - Replace” for the

correct procedure.

Removal Procedure

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Contaminants may cause  rapid wear and  shortened

component life.

g01401675

Illustration 134

g01401970

Illustration 133

1.  Remove bolt (2), clip (3) and spacer (4).

1.  Ensure that hoses (1), (3) and (5) are clean and

free from restriction.

2.  Loosen the hose clamp and remove hose (1) from

the valve mechanism cover base.

2.  If necessary, assemble crankcase breather (4).

Refer to Operation and Maintenance Manual,

“Engine Crankcase Breather - Replace” for the

correct procedure.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

3.  Position crankcase breather (4) on the mounting

bracket and install bolts (2). Tighten the bolts to a

torque of 28 N·m (21 lb ft).

Contaminants may cause  rapid wear and  shortened

component life.

4.  Connect hose (5) to crankcase breather  (4).

Tighten the nut securely.

5.  Connect hose (3) to crankcase breather  (4).

Tighten the clamp securely.

6.  Connect hose (1) to crankcase breather  (4).

Tighten the clamp securely.

This document has been printed from SPI². Not for Resale

 

60

KENR6906

Disassembly and  Assembly Section

g01401675

g01380899

Illustration 135

Illustration 136

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

damage.

2.  Install hose (1) to the valve mechanism cover

base. Tighten the clamp securely.

3.  Install bolt (2), clip (5) and spacer (4). Tighten the

bolt to a torque of 55 N·m (41 lb ft).

i02754820

Valve Mechanism Cover  -

Remove and Install

g01380900

Illustration 137

Tightening sequence for the valve mechanism cover

Removal Procedure

1.  Gradually loosen bolts (2) in reverse numerical

order to the sequence that is shown in Illustration

137. This will help prevent distortion of the valve

mechanism cover.

NOTICE

Keep all parts clean from contaminants.

2.  Remove bolts (2) and isolators (3) from valve

mechanism cover (1).

Contaminants may cause  rapid wear and  shortened

component life.

3.  Remove valve mechanism cover (1) from the

valve mechanism cover base.

4.  Remove joint (4).

This document has been printed from SPI². Not for Resale

 

KENR6906

61

Disassembly and  Assembly Section

Installation Procedure

i02754821

Valve Mechanism Cover Base -

Remove and Install

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Removal Procedure

Start By:

a.  Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01380899

Illustration 138

1.  Install a new joint (4) to the valve  mechanism

cover base.

Note: Ensure that the joint is correctly  located on

the valve mechanism cover base with TOP, FRONT

upward.

2.  Place valve mechanism cover (2) in position and

install isolators (3).

g01398095

Illustration 140

Typical example

1.  Disconnect harness assembly (7) from valve

mechanism cover base (1).

2.  Disconnect harness assembly (2) from electronic

unit injectors (3).

3.  Disconnect hose (6) from separator (5).

4.  Gradually loosen bolts (4). Loosen the outer bolts