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Perkins2506-15拆卸組裝手冊
詳細描述
Disassembly and
Assembly
2506-15 Industrial Engine
M G A (Engine)
MGB (Engine)
M G D (Engine)
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
Note: The crankshaft front seal and the wear sleeve
must be replaced as a unit. Once the crankshaft
front seal and the wear sleeve are separated, these
components can not be used again.
Table 28
Required Tools
Part
Tool
B
Number
GE50008
GE50009
GE50014
GE50013
Part Description
Qty
1
Seal Locator
C
Bolt
3
D
Nut (Seal Installer)
Seal Installer
1
E
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: The crankshaft front seal and the wear
sleeve must be replaced at the same time. Once
the crankshaft front seal and the wear sleeve are
separated, these components cannot be used again.
Note: Do not lubricate the crankshaft seal or the wear
g01044861
sleeve. The crankshaft seal must be installed dry.
Illustration 70
Typical example
1. Before installation of the crankshaft front seal
and the wear sleeve, inspect the crankshaft for
scratches. Also, inspect the crankshaft for any
distortion on the surface that may lead to an out of
round condition. Use a polishing cloth in order to
remove any imperfections on the crankshaft.
1. Use a 4 mm (0.158 inch) drill in order to make
three or more holes in wear sleeve (2).
2. Use Tooling (A) to remove the wear sleeve.
3. Use a 4 mm (0.158 inch) drill in order to make
2. Clean the outside diameter of the crankshaft.
three or more holes in crankshaft front seal (1).
4. Use Tooling (A) to remove crankshaft front seal
(1).
This document has been printed from SPI². Not for Resale
40
KENR6232
Disassembly and Assembly Section
i02554751
Front Cover - Remove
Removal Procedure
Start By:
a. Remove the fan drive. Refer to Disassembly and
Assembly, “Fan drive - Remove”.
b. Remove the assembly of the vibration damper
and the crankshaft pulley. Refer to Disassembly
and Assembly, “Vibration Damper and Pulley -
Remove and Install”.
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.
g01056093
Illustration 71
Typical example
3. Fasten Tooling (B) to the crankshaft with Tooling
(C).
Dispose of all fluids according to local regulations and
mandates.
Note: Install the crankshaft front seal with the arrow
that shows the direction of crankshaft rotation toward
the front of the engine.
NOTICE
Keep all parts clean from contaminants.
4. Position wear sleeve (2) and crankshaft front seal
(1) on Tooling (B). Install Tooling (E) on Tooling
(B). Lubricate the face of the washer on Tooling
(D). Install Tooling (D) on Tooling (B).
Contaminants may cause rapid wear and shortened
component life.
5. Tighten Tooling (D) until Tooling (E) contacts
Tooling (B).
6. Remove Tooling (D) and Tooling (E) from Tooling
(B).
7. Remove Tooling (C) and Tooling (B) from the
crankshaft.
End By:
a. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
g01286405
Illustration 72
1. Loosen bolts (2). Remove front cover (3) from
front housing (1).
This document has been printed from SPI². Not for Resale
KENR6232
41
Disassembly and Assembly Section
2. Remove bolts (2) and seal (4) from front cover (3).
i02554750
Front Cover - Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01286471
Illustration 74
Tightening sequence
2. Position front cover (3) on front housing (1).
Tighten the bolts to a torque of 20 N·m (15 lb ft)
in the numerical sequence that is shown in
Illustration 74.
End By:
a. Install the assembly of the vibration damper
and the crankshaft pulley. Refer to Disassembly
and Assembly, “Vibration Damper and Pulley -
Remove and Install”.
b. Install the fan drive. Refer to Disassembly and
Assembly, “Fan drive - Install”.
g01286405
Illustration 73
1. Install seal (4) and bolts (2) to front cover (3).
i02554763
Gear Group (Front) - Remove
Removal Procedure
Start By:
a. Remove the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove and
Install”.
NOTICE
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
42
KENR6232
Disassembly and Assembly Section
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
Note: Be sure to mark the orientation of each of the
gears for installation purposes.
g01287363
Illustration 77
Typical example
5. Remove bolts (11), plate (12), and idler gear
assembly (10).
g01287358
Illustration 75
1. Remove bolts (2) and thrust plate (1).
g01287364
Illustration 78
2. Remove sealing plate (3) and adapter (4).
Typical example
6. Remove bolts (14), plate (15), and cluster gear
3. Remove O-ring seal (5) and O-ring seal (6) from
assembly (13).
sealing plate (3).
g01287359
Illustration 76
Typical example
4. Remove bolts (8), plate (9), and adjustable idler
gear assembly (7).
This document has been printed from SPI². Not for Resale
KENR6232
43
Disassembly and Assembly Section
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
g01287365
Illustration 79
Typical example
Note: The backlash for the camshaft gear and
the adjustable idler gear assembly will need to be
readjusted at assembly.
7. Remove fasteners (17) and remove stub shaft
g01287373
Illustration 80
Typical example
assembly (16).
8. Remove fasteners (19) and remove stub shaft
1. Install stub shaft (20). Apply Tooling (B) to bolts
(21). Install bolts (21) and tighten to a torque of
55 N·m (40 lb ft) in sequence. (1, 3, 4, 5, 2, 1, 2,
3, 4, 5, 1)
(18).
9. Remove bolts (21) and remove stub shaft (20).
i02554762
Note: If any studs are loose or the threads are
Gear Group (Front) - Install
damaged, install new studs to the front housing.
2. Install stub shaft (18). Apply Tooling (A) to the
studs and the bolt for stub shaft (18). Tighten nuts
(19) and the bolt to a torque of 55 N·m (40 lb ft).
Installation Procedure
3. Install stub shaft assembly (16). Do not tighten
nuts (17) and the bolt for the shaft assembly at
this time. The nuts and the bolt for stub shaft
assembly (16) will need to be tightened when the
backlash is adjusted.
Table 29
Required Tools
Tool
Part Number
Part Description
Qty
POWERPART
A
21820117
1
Note: If shaft assembly (16) is removed, the backlash
for the camshaft gear and the adjustable idler
gear will need to be readjusted. Refer to Systems
Operation, Testing and Adjusting, “Gear Group
(Front) - Time”.
Threadlock and Nutlock
POWERPART
Rubber Grease
B
21820221
1
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
44
KENR6232
Disassembly and Assembly Section
8. Apply Tooling (A) to bolts (14). Position plate
(15) with the oil groove toward the gear face.
Install bolts (14) and tighten to a torque of 28 N·m
(21 lb ft).
g01287363
Illustration 83
Typical example
g01287358
Illustration 81
9. Position idler gear (10) on the shaft assembly.
4. Install new O-ring seals (5) and (6) to sealing plate
10. Apply Tooling (A) to bolts (11). Position plate
(12) with the oil groove toward the gear face.
Install bolts (11) and tighten to a torque of 28 N·m
(21 lb ft).
(3). Lubricate O-ring seal (5) with Tooling (B).
5. Install adapter (4). Ensure that the dowel in the
adapter engages the hole in the camshaft.
11. Install the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove and
Install.” for the correct procedure.
6. Install sealing plate (3) and thrust plate (1) in the
front housing. Apply Tooling (A) to bolts (2). Install
bolts (2) and tighten the bolts to a torque of 12 N·m
(106 lb in). Ensure that sealing plate (3) and O-ring
seal (6) are seated against the cylinder head.
12. Check the backlash for the camshaft gear and
the adjustable idler gear. If necessary, adjust the
backlash. Refer to Systems Operation, Testing
and Adjusting, “Gear Group (Front) - Time”.
Note: Ensure that No. 1 piston at the top center
position on the compression stroke. Refer to Systems
Operation, Testing and Adjusting, “Finding Top
Center Position for No. 1 Piston”.
Note: The camshaft gear must be installed and the
adjustable idler gear must be removed in order to
perform the backlash adjustment procedure.
g01287378
Illustration 82
Typical example
g01288571
Illustration 84
7. Put cluster gear assembly (13) on the stub shaft.
Ensure that Timing Marks (V) are aligned on the
cluster gear assembly and the crankshaft gear.
13. Once the correct backlash has been obtained,
follow Steps 13.a through 13.d in order to secure
stub shaft assembly (16).
This document has been printed from SPI². Not for Resale
KENR6232
45
Disassembly and Assembly Section
a. Remove one nut (17).
b. Remove the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
Sensor - Remove and Install”.
b. Apply Tooling (A) to the nut.
c. Install nut (17) and tighten to a torque of
c. Remove the belt tightener. Refer to Disassembly
55 N·m (40 lb ft).
and Assembly, “Belt Tightener - Remove”.
d. Repeat the procedure for the remaining nuts
d. Remove the fuel transfer pump. Refer to
Disassembly and Assembly, “Fuel Transfer Pump
- Remove”.
and the bolt.
Note: Removing and installing one nut at time will
ensure that the position of the stub shaft assembly
is not affected.
e. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove”.
Note: Ensure that the timing mark on the camshaft
gear is aligned with the timing mark on the front
housing before the adjustable idler gear assembly
is installed.
f. Remove the gear group (front). Refer to
Disassembly and Assembly, “Gear Group (Front)
- Remove ”.
g. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
h. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Install”.
i. Remove the engine support. Refer to Disassembly
and Assembly, “Engine Support (Front) - Remove
and Install”.
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.
g01287359
Illustration 85
Typical example
14. Put adjustable idler gear assembly (7) on the
stub shaft assembly. Position plate (9) with the oil
groove toward the face of the gear. Apply Tooling
(A) to bolts (8). Install bolts (8). Tighten bolts (8)
to a torque of 28 N·m (21 lb ft).
Dispose of all fluids according to local regulations and
mandates.
End By:
NOTICE
Keep all parts clean from contaminants.
a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Install”.
Contaminants may cause rapid wear and shortened
component life.
i02554765
Housing (Front) - Remove
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
Removal Procedure
Start By:
a. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
This document has been printed from SPI². Not for Resale
46
KENR6232
Disassembly and Assembly Section
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
g01286831
Illustration 86
1. Remove bolts (3) and bracket (2).
2. Remove the brackets that support the harness
assembly.
3. Use a suitable lifting device to support the weight
of front housing (1). The front housing weighs
approximately 62 kg (137 lb).
g01286831
Illustration 87
1. Thoroughly clean the mating surfaces of the
cylinder block and front housing (1). Ensure that
the dowels in the cylinder block protrude 1.91 cm
(0.75 inch) from the mating surface.
4. Remove bolts (4).
5. Use the lifting device to remove front housing (1).
6. Remove joint (5).
2. Install a new joint (5) on the dowels in the cylinder
block.
Note: It is not necessary to remove the dowels in the
Note: Trim the joint even with the bottom of the front
cylinder block that locate the front housing.
housing after assembly.
i02554764
3. Use a suitable lifting device to align front housing
(1) with the dowels in the cylinder block. The front
housing weighs approximately 62 kg (137 lb).
Housing (Front) - Install
4. Install front housing (1) to the cylinder block.
Install bolts (4). Tighten the bolts to a torque of
50 N·m (37 lb ft).
Installation Procedure
5. Position bracket (2) and install bolts (3). Ensure
that the bracket that supports the harness
assembly is secured by the appropriate bolt.
Tighten the bolts to a torque of 47 N·m (35 lb ft).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
6. Install the remaining bracket that supports the
harness assembly.
This document has been printed from SPI². Not for Resale
KENR6232
47
Disassembly and Assembly Section
End By:
a. Install the engine support. Refer to Disassembly
and Assembly, “Engine Support (Front) - Remove
and Install”.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Install”.
c. Install the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Install”.
d. Install the gear group (front). Refer to Disassembly
g01286833
and Assembly, “Gear Group (Front) - Install ”.
Illustration 88
1. Loosen clamp (2) and remove hose (3) from
connection (1) on the valve mechanism cover.
Remove the hose.
e. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
f. Install the fuel transfer pump. Refer to Disassembly
Installation Procedure
and Assembly, “Fuel Transfer Pump - Install”.
g. Install the belt tightener. Refer to Disassembly and
NOTICE
Assembly, “Belt Tightener - Install”.
Keep all parts clean from contaminants.
h. Install the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
Sensor - Remove and Install”.
Contaminants may cause rapid wear and shortened
component life.
i. Install the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
i02554701
Crankcase Breather - Remove
and Install
(Open Breather)
Removal Procedure
g01286833
Illustration 89
1. Ensure that hose (3) is clean and free from
NOTICE
damage.
Keep all parts clean from contaminants.
2. Install hose (3) to connection (1) on the valve
Contaminants may cause rapid wear and shortened
component life.
mechanism cover. Tighten clamp (2).
This document has been printed from SPI². Not for Resale
48
KENR6232
Disassembly and Assembly Section
i02554786
Valve Mechanism Cover -
Remove and Install
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01283967
Illustration 91
Tightening sequence for the valve mechanism cover
3. Gradually loosen isolated bolts (1) in reverse
numerical order. Refer to Illustration 91. This will
help prevent distortion of the valve mechanism
cover.
4. Remove the valve mechanism cover (2). Remove
isolated bolts (1) and joint (4) from the valve
mechanism cover.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01283965
Illustration 90
1. Loosen clip (5) and remove breather hose (6) from
valve mechanism cover (2).
2. Disconnect the harness assembly from connector
(3). Remove the bolts and the washers that secure
the connector to valve mechanism cover (2).
g01283965
Illustration 92
1. Install isolated bolts (1) and a new joint (4) to valve
mechanism cover (2).
This document has been printed from SPI². Not for Resale
KENR6232
49
Disassembly and Assembly Section
g01283967
Illustration 93
Tightening sequence for the valve mechanism cover
2. Install valve mechanism cover (2). Gradually
tighten the isolated bolts (1) to a torque of 20 N·m
(15 lb ft) in the numerical sequence that is shown
in Illustration 93.
g01047470
Illustration 94
3. Position connector (3) into valve mechanism cover
(2). Install the bolts and the washers that secure
the connector to the valve mechanism cover.
Torque the bolts to a torque of 1.5 N·m (13 lb in).
Connect the harness assembly to the connector.
Valve rocker arms and unit injector rocker arms
can move on the shaft after the bolts have been
removed. The shaft should be kept level when re-
moved from the cylinder head. To avoid possible
personal injury, keep fingers clear of the valve
rocker arms and the unit injector rocker arms
when lifting the assembly from the cylinder head.
4. Install clip (5) and breather hose (6) to valve
mechanism cover (2).
i02554783
Rocker Arm and Shaft -
Remove
1. Remove bolts (2).
2. Use Tooling (A) to remove rocker arm shaft
assembly (4), valve rocker arms (3), and electronic
unit injector rocker arms (1) as a unit.
Removal Procedure
3. Make a temporary mark on the valve bridges in
order to show the location and the orientation.
Remove the valve bridges from the cylinder head.
Table 30
Required Tools
Part
Note: Identification will ensure that the valve bridges
can be reinstalled in the original location and the
original orientation. Do not interchange the location
or the orientation of used valve bridges.
Tool
Number
Part Description
Qty
A
27610322
Lifting Bracket
1
Start By:
i02554781
Rocker Arm - Disassemble
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
Disassembly Procedure
NOTICE
Keep all parts clean from contaminants.
Start By:
Contaminants may cause rapid wear and shortened
component life.
a. Remove the rocker arms and the rocker shaft.
Refer to Disassembly and Assembly, “Rocker Arm
and Shaft - Remove”.
This document has been printed from SPI². Not for Resale
50
KENR6232
Disassembly and Assembly Section
i02554780
NOTICE
Rocker Arm - Assemble
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Assembly Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01047557
Illustration 95
1. Remove valve rocker arms (11) and electronic unit
injector rocker arm (3) from rocker shaft assembly
(4).
2. Remove nut (7) from adjustment screw (8).
g01047557
Illustration 96
3. Remove adjustment screw (8) from valve rocker
arms (11).
Note: Do not reuse the O-ring seal on the adjustment
screw if the button is removed from the adjustment
screw.
4. Remove button (10) from adjustment screw (8).
Remove O-ring seal (9) from the adjustment
screw.
1. Install a new O-ring seal (9) in button (10).
5. Remove nut (2) from unit injector adjustment
2. Use a soft hammer to seat button (10) on
screw (1).
adjustment screw (8).
6. Remove unit injector adjustment screw (1) from
3. Install adjustment screw (8) in valve rocker arms
electronic unit injector rocker arm (3).
(11). Install nut (7) on the adjustment screw.
7. Remove button (6) from unit injector adjustment
screw (1). Remove O-ring seal (5) from the unit
injector adjustment screw.
4. Install a new O-ring seal (5) in button (6).
5. Use a soft hammer to seat button (6) on unit
injector adjustment screw (1).
6. Install unit injector adjustment screw (1) in
electronic unit injector rocker arm (3). Install nut
(2) on the unit injector adjustment screw.
7. Lubricate rocker shaft assembly (4) with clean
engine oil.
8. Install valve rocker arms (11) and electronic unit
injector rocker arm (3) on rocker shaft assembly
(4).
This document has been printed from SPI². Not for Resale
KENR6232
51
Disassembly and Assembly Section
End By:
3. Install bolts (2) and tighten to a torque of 109 N·m
(80 lb ft).
a. Install the rocker arms and the rocker shaft. Refer
to Disassembly and Assembly, “Rocker Arm and
Shaft - Install”.
4. Adjust the valve lash for the inlet valves and the
exhaust valves. Refer to Systems Operation,
Testing and Adjusting, “Engine Valve Lash
- Inspect/Adjust”. Adjust the electronic unit
injectors. Refer to Systems Operation, Testing and
Adjusting, “Electronic Unit Injector - Adjust”.
i02554782
Rocker Arm and Shaft - Install
End By:
a. Install the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
Installation Procedure
Table 31
Required Tools
i02554713
Tool
Part Number
Part Description
Lifting Bracket
Qty
Cylinder Head - Remove
A
27610322
1
NOTICE
Removal Procedure
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Table 32
Required Tools
Tool
A
Part Number
GE50020
Part Description
Qty
1
1. Install the valve bridges.
Socket
Note: Install used valve bridges in the original
location and in the original orientation. Ensure that the
valve bridges are correctly seated on the valves. New
valve bridges may be installed in either orientation.
B
VP12712
Lifting Bracket
1
Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove”.
b. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
c. Remove the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove”.
d. Remove the water temperature regulator housing.
Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install ”.
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.
g01117306
Illustration 97
2. Use Tooling (A) in order to position rocker arm
shaft assembly (4), valve rocker arms (3), and
electronic unit injector rocker arms (1) as a unit,
on the cylinder head.
Dispose of all fluids according to local regulations and
mandates.
This document has been printed from SPI². Not for Resale
52
KENR6232
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
g01067185
Illustration 99
Typical example
4. Disconnect hose assembly (8) from the front of the
cylinder head. Remove the bolt and the clip that
secures the hose assembly to the cylinder head.
5. Disconnect hose assembly (9) from the rear of the
cylinder head. Remove the bolt and the clip that
secures the hose assembly to the cylinder head.
6. Remove bolt (14), the clip and the spacer. Remove
the crankcase breather from the cylinder head.
7. Remove bolts (7) and remove the bracket from
the cylinder head.
8. Slide the locking tab into the unlocked position
and disconnect the harness assembly from inlet
manifold pressure sensor (10).
g01287358
9. Slide the locking tab into the unlocked position
and disconnect the harness assembly from inlet
manifold temperature sensor (13).
Illustration 98
1. Remove bolts (2) and thrust plate (1).
2. Remove sealing plate (3) and adapter assembly
10. Remove the bolts and the clips that secure the
(4).
harness assembly to the cylinder head.
3. Remove O-ring seal (5) and O-ring seal (6) from
11. Remove bolts (12), the bracket and air inlet elbow
(11) from the cylinder head. Remove the O-ring
seal from the air inlet elbow.
sealing plate (3).
Note: Be sure to mark the orientation of the air inlet
elbow for installation purposes.
This document has been printed from SPI². Not for Resale
KENR6232
53
Disassembly and Assembly Section
g01288987
Illustration 100
Typical example
12. Remove bolts (15) from the front lifting bracket.
g01288989
Illustration 102
Typical example
16. Remove cylinder head gasket (18) and O-ring
seal (19).
17. Remove seal (22) and seals (24).
18. Remove spacer plate (21).
19. Remove O-ring seal (20) from the dowel in the
cylinder block. Remove spacer plate gasket (24).
g01288988
Illustration 101
Typical example
i02554711
Cylinder Head - Install
13. Use Tooling (A) in order to remove cylinder head
bolts (16).
14. Attach Tooling (B) and a suitable lifting device
to cylinder head (17). The weight of the cylinder
head assembly is approximately 235 kg (518 lb).
Ensure that all of the following items are clear
from the cylinder head: harness assemblies, tube
assemblies, and hose assemblies.
Installation Procedure
Table 33
Required Tools
Part
15. Use the lifting device to carefully remove cylinder
Tool
A
Number
GE50020
VP12712
-
Part Description
Qty
1
head (17).
Socket
B
Lifting Bracket
Guide Stud
1
C
2
POWERPART
D
E
F
CV60895
21820221
2182638
1
1
1
Special Lubricant
POWERPART
Rubber Grease
POWERPART
Retaining Compound
This document has been printed from SPI². Not for Resale
54
KENR6232
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01288718
Illustration 104
Typical example
6. Install Tooling (C) to the cylinder block in the
positions that are shown in Illustration 104.
g01288989
Illustration 103
Typical example
Note: Thoroughly clean the spacer plate and the
bottom surface of the cylinder head and the top of
the cylinder block. A new spacer plate gasket and
a cylinder head gasket must be installed when the
cylinder head is removed.
g01288988
Illustration 105
Typical example
1. Install O-ring seal (20) on the dowel in the cylinder
7. Attach Tooling (A) and a suitable lifting device to
cylinder head (17). The weight of cylinder head
assembly (17) is approximately 235 kg (518 lb).
block.
Note: Ensure that the dowel protrudes from
the face of the cylinder block by 20 ± 0.5 mm
(0.79 ± 0.02 inch).
8. Use the lifting device to align cylinder head (17)
with Tooling (C). Carefully install the cylinder head
onto the dowel pins in the cylinder block.
2. Install spacer plate gasket (23) on the cylinder
block.
9. Remove Tooling (A).
3. Install spacer plate (21).
10. Apply Tooling (D) to the threads of cylinder head
bolts (16) and both sides of the washers. Install
cylinder head bolts (16).
4. Install seals (24) and seal (22).
5. Install cylinder head gasket (18) on the spacer
plate. Install O-ring seal (19) on the dowel in the
cylinder block.
g01072801
Illustration 106
This document has been printed from SPI². Not for Resale
KENR6232
55
Disassembly and Assembly Section
Note: The bolts that are Marked “X” are 216 mm
(8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24, and
26. The rest of the bolts are 194 mm (7.6 inch) long.
15. Connect hose assembly (8) to the cylinder head.
Install the bolt and the clip that secures the hose
assembly to the cylinder head.
11. Tighten the cylinder head bolts according to the
16. Install bolt (14), the clip and the spacer that
secures the breather tube to the cylinder head.
Tighten bolt (14) to a torque of 10 N·m (89 lb in).
following procedure.
a. In the numerical sequence, tighten Bolts 1
through 26 to a torque of 270 N·m (200 lb ft).
17. Position the bracket on the cylinder head and
install bolts (7). Tighten the bolts to a torque of
47 N·m (35 lb ft).
b. In the numerical sequence, tighten Bolts 1
through 26 to a torque of 450 N·m (330 lb ft).
18. Connect the harness assembly to inlet manifold
pressure sensor (10). Slide the locking tab into
the locked position.
c. In the numerical sequence, again tighten Bolts
1 through 26 to a torque of 450 N·m (330 lb ft).
19. Connect the harness assembly to inlet manifold
temperature sensor (13). Slide the locking tab into
the locked position.
20. Install the bolts and the clips that secure the
harness assembly to the cylinder head.
g01288987
Illustration 107
12. Install bolts (15) to the front lifting bracket. Tighten
the bolts to a torque of 105 N·m (77 lb ft).
g01287358
Illustration 109
21. Install O-ring seal (5) and O-ring seal (6) on
sealing plate (3). Lubricate O-ring seal (5) with
Tooling (E).
g01067185
,Illustration 108
Typical example
22. Install adapter assembly (4) and sealing plate (3).
Ensure that the dowel in adapter assembly (4)
engages the hole in the camshaft.
13. Install a new O-ring seal to air inlet elbow (11).
Position the bracket and air inlet elbow (11) on the
cylinder head. Install bolts (12) and tighten to a
torque of 47 N·m (35 lb ft).
Note: Ensure that the O-ring seal stays in the groove
in sealing plate (3).
23. Install thrust plate (1). Apply Tooling (F) to bolts
(2). Hold the thrust plate in position and install
bolts (2). Evenly tighten bolts (2) to a torque of
12 N·m (106 lb in).
Note: Ensure that the air inlet elbow is installed in the
correct orientation.
14. Connect hose assembly (9) to the cylinder head.
Install the bolt and the clip that secures the hose
assembly to the cylinder head.
This document has been printed from SPI². Not for Resale
56
KENR6232
Disassembly and Assembly Section
Note: Ensure that the O-ring seal stays in the groove
in sealing plate (3).
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
End By:
a. Install the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Install”.
b. Install the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Install”.
c. Install the water temperature regulator housing.
Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install”.
d. Install the turbocharger. Refer to Disassembly and
Assembly, “Turbocharger - Install”.
i02554691
Camshaft - Remove
Removal Procedure
Table 34
g01287358
Illustration 110
Required Tools
1. Remove bolts (2) and thrust plate (1).
Tool
A
Part Number
GE50018
GE50017
GE50015
GE50025
Part Description
Qty
1
Cradle
2. Remove sealing plate (3) from the front housing.
Remove adapter assembly (4) from the camshaft.
B
Guide
1
C
Camshaft Pilot
Camshaft Hook
2
3. Remove O-ring seal (5) and O-ring seal (6) from
sealing plate (3).
D
2
NOTICE
Start By:
Care must be used when removing or installing the
camshaft. Do not damage the finshed surfaces of the
camshaft or the camshaft bearings.
a. Remove the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove and
Install”.
b. Remove the rocker arms and the rocker shafts.
Refer to Disassembly and Assembly, “Rocker Arm
and Shaft - Remove”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01286820
Illustration 111
Typical example
This document has been printed from SPI². Not for Resale
KENR6232
57
Disassembly and Assembly Section
4. Use the bolts for the rocker arm shaft assembly to
install Tooling (A) at Location (Y).
g01047996
Illustration 115
Typical example
g01047945
Illustration 112
Typical example
7. Move camshaft (8) forward and install one Tooling
(C) to the end of the camshaft. Again, move the
camshaft forward and install remaining Tooling (C)
to the back of first Tooling (C). Align camshaft (8)
with the bore of Tooling (B). Tighten the bolts that
hold Tooling (B) to front housing (7).
5. Install Tooling (B) on front housing (7). Tooling (B)
is used to support camshaft (8). Do not tighten the
bolts for Tooling (B) at this time.
Note: Tooling (C) will support the rear of the camshaft
as the camshaft is moved out of the cylinder head
and into Tooling (B).
8. Use Tooling (D) to move camshaft (8) toward the
front of the engine. Reposition Tooling (D), as
required.
Note: Avoid lifting the camshaft with Tooling (D). The
camshaft should rest on Tooling (A). Lifting of the
camshaft can cause misalignment as the camshaft
is removed, resulting in damage to the camshaft
bearings.
g01056675
Illustration 113
Typical example
9. Carefully slide the camshaft to the front of the
engine for removal. Use two people to remove
the camshaft. Keep the camshaft level while the
camshaft is being removed from the cylinder
head. The weight of camshaft (8) is approximately
39 kg (86 lb).
6. Remove Torx screws (9) and cover (10). Remove
the O-ring seal from the cover.
Note: Rotate the camshaft during removal. This will
prevent the camshaft from binding in the camshaft
bearings.
10. Remove Tooling (C) from the camshaft.
11. Remove Tooling (B) from front housing (7).
12. Remove Tooling (A) from the cylinder head.
g01287879
Illustration 114
This document has been printed from SPI². Not for Resale
58
KENR6232
Disassembly and Assembly Section
i02554692
Camshaft - Install
Installation Procedure
Table 35
Required Tools
Tool
A
Part Number
GE50018
GE50017
GE50015
GE50025
GE50016
Part Description
Qty
1
Cradle
B
Guide
1
g01286820
Illustration 116
C
Camshaft Pilot
Camshaft Hook
Alignment Sleeve
2
2. Install Tooling (A) on the cylinder head at Location
D
2
(Y).
H
1
POWERPART
Rubber Grease
J
21820221
1
POWERPART
Thread Lock and Nut
Lock
K
21820117
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01056901
NOTICE
Illustration 117
Typical example
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
3. Install Tooling (B) on front housing (7). Do not
tighten the bolts that hold Tooling (B) to front
housing (7) at this time.
4. Use Tooling (H) to align Tooling (B) with the
camshaft bearings. Tighten the bolts that hold
Tooling (B) to front housing (7). Remove Tooling
(H).
NOTICE
Care must be used when removing or installing the
camshaft. Do not damage the finshed surfaces of the
camshaft or the camshaft bearings.
Note: Tooling (H) should move freely from the bore
of Tooling (B).
1. Ensure that the camshaft and camshaft bearings
are thoroughly clean. Lubricate the camshaft
bearings with clean engine oil.
This document has been printed from SPI². Not for Resale
KENR6232
59
Disassembly and Assembly Section
g01293986
Illustration 118
Typical example
5. Install both Tooling (C) to the rear of camshaft (8).
6. Use two people to install the camshaft. Use
Tooling (D) to assist in aligning camshaft (8)
with the camshaft bearings. Carefully slide the
camshaft into the cylinder head from the front of
the engine. Keep the camshaft level while the
camshaft is being installed in the cylinder head.
The weight of camshaft (8) is approximately 39 kg
(86 lb).
g01287358
Illustration 120
11. Install O-ring seals (5) and (6) in sealing plate (3).
Lubricate O-ring seal (5) with a Tooling (J).
12. Install adapter assembly (4) and sealing plate (3).
Ensure that the dowel in adapter assembly (4)
engages the hole in the camshaft.
Note: Rotate the camshaft during installation. This
will prevent the camshaft from binding in the camshaft
bearings.
Note: Ensure that the O-ring seal stays in the groove
in sealing plate (3).
7. Remove Tooling (C) when camshaft (8) is fully
13. Install thrust plate (1). Apply Tooling (K) to bolts
(2). Hold the thrust plate in position and install
bolts (2). Evenly tighten bolts (2) to a torque of
12 N·m (106 lb in).
installed in the bore.
8. Remove Tooling (A) from the cylinder head.
9. Remove Tooling (B) from the front housing.
Note: Ensure that the O-ring seal stays in the groove
in sealing plate (3).
14. Lubricate the camshaft lobes with clean engine
oil.
End By:
a. Install the camshaft gear. Refer to Disassembly
and Assembly, “Camshaft Gear - Remove and
Install”.
b. Install the rocker arms and the rocker shafts.
Refer to Disassembly and Assembly, “Rocker
Arms and Shaft - Install”.
g01056675
Illustration 119
10. Install a new O-ring seal on cover (10). Position
the cover on the rear of the cylinder head. Install
torx screws (9) and tighten to a torque of 6 N·m
(53 lb in).
This document has been printed from SPI². Not for Resale
60
KENR6232
Disassembly and Assembly Section
i02554695
Camshaft Gear - Remove and
1. Position the No. 1 piston at the top center of the
compression stroke. Refer to Systems Operation,
Testing and Adjusting, “Finding Top Center
Position for No. 1 Piston”.
Install
2. Verify that the timing mark on camshaft gear (1) is
aligned with Timing Mark (X) on front housing (3).
Removal Procedure
Table 36
Required Tools
Tool
Part Number
Part Description
Guide Stud
Qty
A
GE50019
1
Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove”.
NOTICE
g01286832
Illustration 122
Keep all parts clean from contaminants.
3. Remove one bolt (2). Install Tooling (A).
Contaminants may cause rapid wear and shortened
component life.
4. Remove the remaining bolts (2) and remove
camshaft gear (1).
NOTICE
Installation Procedure
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
Table 37
Required Tools
Tool
Part Number
Part Description
Guide Stud
Qty
A
GE50019
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Do not turn the crankshaft or the camshaft while the
camshaft gear is removed. If the front gear group is
not correctly timed during installation, interference can
occur between the pistons and the valves, resulting in
damage to the engine.
g01286828
Illustration 121
This document has been printed from SPI². Not for Resale
KENR6232
61
Disassembly and Assembly Section
g01286832
g00593987
Illustration 123
Illustration 125
Torque sequence for the camshaft gear
1. Align the hole in the back of camshaft gear (1) with
the dowel in the adapter. Position camshaft gear
(1) onto Tooling (A) and install the camshaft gear.
4. Tighten the bolts for the camshaft gear in a
numeric sequence 1, 4, 2, 5, 3, 6, 1, 4 to a torque
of 240 N·m (180 lb ft).
5. Check the backlash between the camshaft gear
and the adjustable idler gear. The backlash should
be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer
to Systems Operation, Testing and Adjusting,
“Gear Group (Front) - Time” for the backlash
adjustment procedure.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Install”.
i02554694
Camshaft Bearings - Remove
Removal Procedure
g01286828
Illustration 124
Table 38
Note: Camshaft timing is critical. The timing mark on
the camshaft gear must be aligned with the timing
mark on the front cover when the No. 1 piston is at
the top center of the compression stroke. Refer to
Systems Operation,Testing and Adjusting, “Gear
Group (Front) - Time”.
Required Tools
Part
Tool
Number
27610271
27610312
27610313
27610314
Part Description
Qty
1
Camshaft Bearing Tool
Group
A
2. Verify that the timing mark on camshaft gear (1) is
Camshaft Bearing Pilot
1
aligned with Timing Mark (X) on front housing (3).
B
Taperlock Stud
1
1/2 - 13 by 1 9/16 inch
Note: If the timing marks are not aligned, remove
camshaft gear (1) and rotate the camshaft until the
timing marks are aligned.
C
Puller Plate
1
Start By:
3. Install bolts (2) finger tight. Remove Tooling (A)
and install the remaining bolt (2).
a. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”.
This document has been printed from SPI². Not for Resale
62
KENR6232
Disassembly and Assembly Section
i02554693
Camshaft Bearings - Install
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Installation Procedure
Table 39
Required Tools
Part
Tool
Number
27610271
27610312
27610313
Part Description
Qty
1
Camshaft Bearing Tool
Group
A
Camshaft Bearing Pilot
1
B
Taperlock Stud
1
1/2 - 13 by 1 9/16 inch
C
D
27610314
27610315
27610316
Puller Plate
1
1
1
g01159745
Alignment Bushing
Backup Plate
Illustration 126
1. Remove the No. 7 camshaft bearing (rear). Work
from the rear of the engine to the front of the
engine.
E
F
Bolt
27610317
27610318
1
1
1/2 - 13 by 1 inch
Spacer Plate
2. Install the small end of Tooling (B) in camshaft
bearing (1).
NOTICE
Keep all parts clean from contaminants.
3. Position Tooling (C) over Tooling (A). Install
Tooling (A) through the cylinder head on Tooling
(B).
Contaminants may cause rapid wear and shortened
component life.
Note: Tooling (C) is installed on the outside of the
cylinder head. Tooling (C) is required in order to
remove all the camshaft bearings from the cylinder
head.
4. Use Tooling (A) to remove camshaft bearing (1)
from the cylinder head.
5. Remove Tooling (B) from Tooling (A) and remove
the camshaft bearing.
g01159754
Illustration 127
1. Install the No. 7 camshaft bearing (rear), as
follows:
a. Insert the large end of Tooling (B) into the No.
7 camshaft bore.
b. Position Tooling (C) over Tooling (A). Install
Tooling (A) through the cylinder head on
Tooling (B).
This document has been printed from SPI². Not for Resale
KENR6232
63
Disassembly and Assembly Section
c. Position camshaft bearing (1) on Tooling (B).
Install Tooling (E) on Tooling (B).
Note: Refer to Specifications, “Cylinder Head” for
appropriate information for the orientation of the
camshaft bearings in the cylinder head.
d. Use Tooling (A) in order to pull camshaft
bearing (1) into the camshaft bore.
Note: When the chamfer of Tooling (E) contacts the
face of the camshaft bore, the camshaft bearing is
properly installed.
g01159758
Illustration 129
3. Install the No. 1 camshaft bearing (front), as
follows:
a. Insert the large end of Tooling (B) into the No.
1 camshaft bore. Assemble Tooling (A) and
Tooling (D) on Tooling (B).
b. Position camshaft bearing (1) on Tooling (B).
Install Tooling (E) and Tooling (F) on Tooling
(B).
Note: Refer to Specifications, “Cylinder Head” for
appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.
g01159756
Illustration 128
2. Install the No. 6 through No. 2 camshaft bearings,
as follows:
Note: Tooling (F) is used to seat the No. 1 camshaft
a. Insert the large end of Tooling (B) into the
bearing to the correct depth in the camshaft bore.
camshaft bore.
c. Use Tooling (A) in order to pull the No. 1
camshaft bearing into the No. 1 camshaft bore.
When the chamfer of Tooling (E) contacts
the face of the camshaft bore, the camshaft
bearing is properly installed.
Note: Use Tooling (D) to align Tooling (A) and Tooling
(B) with the camshaft bearing bores. Install Tooling
(D) in the inside diameter of any installed camshaft
bearing between Tooling (A) and Tooling (B).
b. Install Tooling (A) on Tooling (B). Position
camshaft bearing (1) on Tooling (B). Install
Tooling (E) on Tooling (B).
End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
Note: Refer to Specifications, “Cylinder Head” for
appropriate information for the location and the
orientation of the camshaft bearings in the cylinder
head.
c. Use Tooling (A) in order to pull camshaft
bearing (1) into the camshaft bore.
Note: When the chamfer of Tooling (E) contacts the
face of the camshaft bore, the camshaft bearing is
properly installed.
This document has been printed from SPI². Not for Resale
64
KENR6232
Disassembly and Assembly Section
i02554730
Engine Oil Pan - Remove and
Install
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
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.
g01284906
Illustration 130
Typical example
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
2. Remove drain plug (3). Remove washer (2) from
drain plug (3).
3. Loosen bolts (5). Remove engine oil pan (4).
1. Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, “Engine Oil - Change”.
4. Remove bolts (5) and seal (1) from engine oil pan
(4).
Installation Procedure
Table 40
Required Tools
Part
Tool
Number
Part Description
Qty
A
CH10888
Silicone Gasket
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Clean the mating surfaces of the engine oil pan,
cylinder block, front housing, and the flywheel
housing.
This document has been printed from SPI². Not for Resale
KENR6232
65
Disassembly and Assembly Section
3. Apply a bead of Tooling (A) to positions (X).
g01284984
Illustration 133
Tightening sequence
4. Install engine oil pan (4). Tighten bolts (5) in the
numerical sequence that is shown in Illustration
133. Tighten the bolts to a torque of 47 N·m
(35 lb ft).
5. Install a new washer (2) to drain plug (3). Install
drain plug (3) to engine oil pan (4). Tighten the
drain plug to a torque of 45 N·m (33 lb ft).
g01284906
Illustration 131
Typical example
6. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
- Change”.
2. Install seal (1) and bolts (5) to engine oil pan (4).
i02554715
Cylinder Liner - Remove
Removal Procedure
Table 41
Required Tools
Part
Tool
Part Description
Qty
Number
A
GE50001
Cylinder Liner Puller
1
Start By:
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01285214
Illustration 132
Typical example
This document has been printed from SPI². Not for Resale
66
KENR6232
Disassembly and Assembly Section
1. Make temporary identification marks in order to
show the location of the cylinder liners.
g01111530
Illustration 135
2. Install liner seals (3) on cylinder liner (1).
g01111472
Illustration 134
3. Apply Tooling (C) on the cylinder block liner bore
2. Use Tooling (A) to remove cylinder liner (1).
surfaces and liner seals (3).
3. Remove liner seals (3) and filler band (2) from
4. Dip filler band (2) in clean engine oil for a
moment. Install the filler band on the cylinder liner
immediately.
cylinder liner (1).
i02554714
Cylinder Liner - Install
5. Use Tooling (B) to install cylinder liner (1) in the
cylinder block. Ensure that any marks in relation
to the cylinder liner projection are in alignment.
End By:
Installation Procedure
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Install”.
Table 42
Required Tools
Tool
Part Number
Part Description
Qty
i02554770
Piston Cooling Jets - Remove
and Install
B
GE50000
Cylinder Liner Installer
1
POWERPART
Rubber Grease
C
21820221
1
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
Contaminants may cause rapid wear and shortened
component life.
Table 43
Required Tools
Note: Ensure that the cylinder liners and the cylinder
Tool
Part Number
Part Description
Qty
block are clean and free from damage.
A
CH11148
Engine Turning Tool
1
1. Check the cylinder liner projection. Refer to
Systems Operation, Testing and Adjusting,
“Cylinder Liner Projection - Inspect”.
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Remove”.
This document has been printed from SPI². Not for Resale
KENR6232
67
Disassembly and Assembly Section
2. Position piston cooling jet (2) in the cylinder block.
Install bolt (1). Tighten the bolt to a torque of
40 N·m (30 lb ft).
NOTICE
Keep all parts clean from contaminants.
Note: Ensure that the nozzles of the piston cooling
Contaminants may cause rapid wear and shortened
component life.
jet are not damaged or distorted.
End By:
a. Install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”.
i02554775
Pistons and Connecting Rods
- Remove
Removal Procedure
g01103621
Illustration 136
Table 45
1. Use Tooling (A) to rotate the crankshaft in order to
Required Tools
gain access to the piston cooling jet.
Tool
Part Number
Part Description
Qty
2. Remove bolt (1) and piston cooling jet (2).
A
CH11148
Engine Turning Tool
1
Installation Procedure
Start By:
Table 44
a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
Required Tools
Tool
Part Number
Part Description
Qty
b. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Remove”.
A
CH11148
Engine Turning Tool
1
NOTICE
c. Remove the piston cooling jets. Refer to
Disassembly and Assembly, “Piston Cooling Jets
- Remove and Install”.
Keep all parts clean from contaminants.
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.
g01103621
Illustration 137
1. Use Tooling (A) to rotate the crankshaft in order to
gain access to the piston cooling jet.
This document has been printed from SPI². Not for Resale
68
KENR6232
Disassembly and Assembly Section
i02554773
Pistons and Connecting Rods
- Disassemble
Disassembly Procedure
Table 46
Required Tools
Part
Tool
A
Number
Part Description
Retaining Ring Pliers
Piston Ring Expander
Qty
1
g00998389
Illustration 138
-
-
B
1
1. Use Tooling (A) to rotate the crankshaft until the
piston is at the bottom center.
Start By:
2. Remove the carbon ridge from the top inside
surface of the cylinder liner.
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
3. Inspect the connecting rod and connecting rod cap
for the proper identification mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting
rod and the connecting rod cap, if necessary.
Note: Mark the components of each piston and
connecting rod assembly. The components must be
reinstalled in the original location. Do not interchange
components.
Note: Do not stamp the connecting rod assembly.
Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
4. Remove bolts (1) and connecting rod bearing cap
(2). Push the connecting rod until the piston rings
are out of the cylinder liner.
g00998390
Illustration 139
5. Remove piston (3) and the connecting rod from
the cylinder liner.
Note: Be careful not to damage the cylinder liner
or the crankshaft journal during the removal of the
piston and the connecting rod.
g01017728
Illustration 140
This document has been printed from SPI². Not for Resale
