KENR6247

May 2007

Disassembly and
Assembly
1104D (Mech) Industrial Engine
NK (Engine)
NL (Engine)
NM (Engine)

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

KENR6247

Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump and Fuel Filter Base - Remove
and Install ............................................................. 4
Fuel Injection Lines - Remove and Install .............. 5
Fuel Injector Cover - Remove and Install ............... 7
Fuel Injection Pump - Remove .............................. 8
Fuel Injection Pump - Install .................................. 9
Fuel Injection Pump Gear - Remove ..................... 11
Fuel Injection Pump Gear - Install ........................ 13
Fuel Injector - Remove ........................................ 14
Fuel Injector - Install ............................................ 15
Turbocharger - Remove ........................................ 15
Turbocharger - Install ............................................ 17
Exhaust Manifold - Remove and Install ............... 18
Exhaust Elbow - Remove and Install ................... 20
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 21
Inlet and Exhaust Valves - Remove and Install .... 23
Engine Oil Filter Base - Remove and Install ........ 26
Engine Oil Cooler - Remove ................................. 27
Engine Oil Cooler - Install ..................................... 28
Engine Oil Relief Valve - Remove and Install (Engines
Without a Balancer Unit) ..................................... 29
Engine Oil Relief Valve - Remove and Install (Engines
with a Balancer Unit) ........................................... 30
Engine Oil Pump - Remove and Install (Engines
Without a Balancer Unit) ..................................... 32
Water Pump - Remove ......................................... 34
Water Pump - Install ............................................. 35
Water Temperature Regulator - Remove and Install
............................................................................. 36
Flywheel - Remove ............................................... 38
Flywheel - Install ................................................... 39
Crankshaft Rear Seal - Remove ........................... 40
Crankshaft Rear Seal - Install ............................... 41
Flywheel Housing - Remove and Install .............. 42
Crankshaft Pulley - Remove and Install (Engines
With an Automatic Belt Tensioner) ...................... 44
Crankshaft Pulley - Remove and Install (Engines
Without an Automatic Belt Tensioner) ................. 45
Crankshaft Front Seal - Remove and Install ......... 46
Crankshaft Wear Sleeve (Front) - Remove and
Install ................................................................... 47
Front Cover - Remove and Install ......................... 49
Gear Group (Front) - Remove and Install ............. 50
Idler Gear - Remove ............................................. 53
Idler Gear - Install ................................................. 56
Housing (Front) - Remove .................................... 59
Housing (Front) - Install ........................................ 61
Accessory Drive - Remove and Install ................. 63
Crankcase Breather - Remove and Install
(Turbocharged Engines with Unfiltered
Breather) ............................................................. 65
Crankcase Breather - Remove and Install
(Turbocharged Engines with Filtered Breather) .. 67
Crankcase Breather - Remove and Install (Naturally
Aspirated Engines) .............................................. 69
Valve Mechanism Cover - Remove and Install ..... 71

3
Table of Contents

Rocker Shaft and Pushrod - Remove ................... 72

Rocker Shaft - Disassemble ................................ 73
Rocker Shaft - Assemble ..................................... 74
Rocker Shaft and Pushrod - Install ....................... 75
Cylinder Head - Remove ...................................... 76
Cylinder Head - Install .......................................... 78
Lifter Group - Remove and Install ......................... 81
Camshaft - Remove and Install ........................... 82
Camshaft Gear - Remove and Install .................. 84
Camshaft Bearings - Remove and Install ............ 86
Engine Oil Pan - Remove and Install (Aluminum and
Pressed Steel Oil Pans) ...................................... 87
Engine Oil Pan - Remove and Install (Cast Iron Oil
Pan) .................................................................... 90
Balancer - Remove ............................................... 93
Balancer - Install ................................................... 95
Piston Cooling Jets - Remove and Install ............. 97
Pistons and Connecting Rods - Remove .............. 99
Pistons and Connecting Rods - Disassemble ..... 100
Pistons and Connecting Rods - Assemble ......... 101
Pistons and Connecting Rods - Install ................ 103
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................. 105
Connecting Rod Bearings - Install (Connecting rods
in position) ......................................................... 106
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position) ..................................... 108
Crankshaft - Remove ........................................... 112
Crankshaft - Install ............................................... 114
Crankshaft Gear - Remove and Install ............... 117
Bearing Clearance - Check .................................. 118
Glow Plugs - Remove and Install ........................ 119
V-Belts - Remove and Install (Engines Without an
Automatic Belt Tensioner ) ................................ 121
Alternator Belt - Remove and Install (Engines With
an Automatic Belt Tensioner) ............................ 122
Fan - Remove and Install ................................... 123
Fan Drive - Remove and Install ......................... 124
Alternator - Remove (Engines With an Automatic Belt
Tensioner) ......................................................... 125
Alternator - Remove (Engines Without an Automatic
Belt Tensioner) .................................................. 125
Alternator - Install (Engines With an Automatic Belt
Tensioner) ......................................................... 126
Alternator - Install (Engines Without an Automatic
Belt Tensioner) .................................................. 127
Electric Starting Motor - Remove and Install ..... 127
Air Compressor - Remove and Install ................ 128
Vacuum Pump - Remove and Install .................. 133

Index Section
Index ................................................................... 135

4
Disassembly and Assembly Section

KENR6247

Disassembly and Assembly

Section
i02628881

Fuel Priming Pump and Fuel

Filter Base - Remove and
Install

Removal Procedure
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Put identification marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.

Illustration 1

g01318612

Typical example

1. Isolate the fuel supply.

2. Isolate the electrical supply.
3. Disconnect plastic tube assemblies (4) and (5)
from fuel priming pump (3).
4. Disconnect plastic tube assembly (2) from fuel
priming pump (3).
5. Plug all the connections on fuel priming pump (3)
and plastic tube assemblies (4) and (5).
6. Disconnect the harness assembly from fuel
priming pump(3).
7. Support the fuel priming pump. Remove bolts and
washers (1) and remove fuel priming pump (3).
Note: Note the location and the orientation of the
brackets for the tube assemblies.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

5
Disassembly and Assembly Section

i02628850

Fuel Injection Lines - Remove

and Install
Removal Procedure
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Illustration 2

g01318612

Typical example

1. Ensure that the fuel priming pump is clean and

free from wear or damage. If necessary, replace
the fuel priming pump as a complete assembly.
2. Position the fuel priming pump (3) onto the cylinder
head. Install bolts and washers (1). Ensure that
any brackets that are retained by the bolts are
installed in the correct position. Tighten the bolts
to a torque on 9 Nm (80 lb in).
3. Remove all plugs from the fuel priming pump and
from the plastic tube assemblies. Connect plastic
tube assemblies (4) and (5) to fuel priming pump
(3).
4. Connect plastic tube assembly (2) to fuel priming
pump (3).
5. Install the harness assembly to fuel priming pump
(3).
6. Restore the fuel supply.
7. Restore the electrical supply.
8. Remove the air from the fuel system. Refer
to Operations and Maintenance Manual, Fuel
System - Prime.

1. Isolate the fuel supply.

2. Isolate the electrical supply.
3. If the engine is equipped with a cover over the fuel
injectors remove the cover. Refer toDisassembly
and Assembly, Fuel Injector Cover - Remove and
Install.
4. Remove the breather tube from the valve
mechanism cover. Refer toDisassembly and
Assembly, Crankcase Breather- Remove and
Install.

6
Disassembly and Assembly Section

KENR6247

10. Plug and cap all open ports, fuel injection lines
and all tube assemblies.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Inspect the fuel injection lines for damage.
Replace any components that are damaged.

Illustration 3

g01343040

5. Loosen the clip and disconnect plastic tube

assembly (3) from fuel priming pump (5).
6. Loosen the clip and disconnect plastic tube
assembly (4) from the fuel return.
7. Remove plastic tube assembly (6).
8. Disconnect fuel injection lines (2) at fuel injectors
(1).

Illustration 5

g01343040

Typical example

Illustration 4

g01319327

Typical example

9. Disconnect fuel injection lines (2) at fuel injection

pump (7). Ensure that connections (8) do not turn.

Illustration 6

g01319327

KENR6247

2. Remove the caps from fuel injection pump (7) and

from fuel injectors (1). Remove the caps from fuel
injection lines (2).
3. Install fuel injection lines(2). Loosely connect the
nuts at both ends of the fuel injection lines.

7
Disassembly and Assembly Section

i02628851

Fuel Injector Cover - Remove

and Install

4. Tighten fuel injection lines (2) at fuel injector (1) to

a torque of 30 Nm (22 lb ft).

Removal Procedure

5. Tighten fuel injection lines (2) at fuel injection

pump (7) to 30 Nm (22 lb ft). Ensure that the
connection (8) does not turn.

NOTICE
Keep all parts clean from contaminants.

Note: Ensure that each fuel injection line does not

contact any other fuel injection line or any other
engine component.

Contaminants may cause rapid wear and shortened

component life.

6. Remove the caps from fuel priming pump (5) and

from the plastic tube assemblies.
7. Connect plastic tube assembly (4) to the fuel
return. Secure the plastic tube assembly with the
clip.
8. Connect plastic tube assembly (3) to the fuel
priming pump. Secure the plastic tube assembly
with the clip.
9. Install plastic tube assembly (6).
10. Install the breather tube to the valve mechanism
cover. Refer toDisassembly and Assembly,
Crankcase Breather- Remove and Install.
11. If the engine is equipped with a cover over the fuel
injectors install the cover. Refer toDisassembly
and Assembly, Fuel Injector Cover - Remove and
Install.
12. Restore the fuel supply.
13. Restore the electrical supply.
14. Remove the air from the fuel system. Refer to
the Operations and Maintenance Manual, Fuel
System - Prime.

Illustration 7

g01319811

Typical example

1. Thoroughly clean all of the outer surfaces of cover

(1).
2. Remove bolts (2) from the cover (1).
3. Remove cover (1).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

8
Disassembly and Assembly Section

KENR6247

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01319811

Illustration 8
Typical example

1. Thoroughly clean all of the inner surfaces of cover

(1).
2. Install cover (1).
3. Install bolts (2). Tighten bolts (2) to a torque of
9 Nm (7 lb ft).

Note: Put identification marks on all hoses, on all

hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
1. Isolate the fuel supply.
2. Isolate the electrical supply.

i02744499

Fuel Injection Pump - Remove

Removal Procedure
Table 1

Required Tools
Tool

Part
Number

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

A2

Part Name

Qty

Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.

Illustration 9

g01349817

Typical example

3. Disconnect plastic tube assemblies (1) and (8)

from the fuel injection pump (4).
4. Disconnect tube assembly (3) from the fuel
injection pump (4).

KENR6247

9
Disassembly and Assembly Section

5. Remove the fuel injection lines. Refer to

Disassembly and Assembly, Fuel Injection Lines
- Remove.
6. Remove tube assembly (2).
7. Disconnect the harness assembly from solenoid
(7).
8. Disconnect the harness assembly from solenoid
(9).
9. 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.
10. Use Tooling (B) in order to lock the camshaft in
the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, Gear Group (Front)
- Remove for the correct procedure.
11. Remove the backlash from the fuel pump gear.
Lock the fuel injection pump in the correct
position and remove the fuel pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear Remove and Install for the correct procedure.
12. Loosen locking screw (5). Rotate spacer (6) in
order to allow locking screw (5) to tighten against
the shaft of the fuel injection pump. Rotate the
fuel injection pump gear in a counterclockwise
direction in order to remove the backlash. Tighten
locking screw (5) to a torque of 17 Nm (13 lb ft).
Note: Locking screw (5) must be tightened in order
to prevent the shaft of the fuel injection pump from
rotating. The shaft of the fuel injection pump must
not be rotated after the fuel injection pump has been
removed from the engine.

g01349818

Illustration 10

13. Remove nut (15). Remove bolt (14).

14. Remove bolt (16) and bracket (13) from the
cylinder block.
15. Remove bolts (10) and washers (11) in order to
remove the fuel injection pump (4).
Note: The fuel injection pump should be supported
by hand as the bolts are removed.
16. Remove the fuel injection pump from the front
housing. Remove O-ring seal (12).
i02744500

Fuel Injection Pump - Install

Installation Procedure
Table 2

Required Tools
Tool

Part
Number

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

21820221

POWERPART
Rubber Grease

A2

Part Name

Qty

10
Disassembly and Assembly Section

KENR6247

5. Install bolts (8). Tighten bolts (8) to a torque of

25 Nm (18 lb ft).

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Inspect the bore in the front housing for damage.
If the bore is damaged, replace the front
housing. Refer to Disassembly and Assembly,
Housing (Front) - Remove and Disassembly and
Assembly, Housing (Front) - Install.

6. Position support bracket (11) onto the cylinder

block. Install bolt (14) finger tight.
7. Install bolt (12) and nut (13) finger tight.
8. Tighten bolt (14) to a torque of 44 Nm (32 lb ft).
Tighten bolt (12) and nut (13) to a torque of
22 Nm (16 lb ft).
Note: Ensure that the fuel injection pump is not
stressed as the bolts for the bracket are tightened.
9. Ensure that the No. 1 cylinder is at top dead center
on the compression stroke. Refer to Systems
Operation, Testing and Adjusting, Fuel Injection
Timing - Check. If necessary, 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.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
10. Use Tooling (B) in order to lock the camshaft in
the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, Gear Group (Front)
- Remove for the correct procedure.
11. Install the fuel injection pump gear to fuel injection
pump (4). Refer to Disassembly and Assembly,
Fuel Injection Pump Gear - Install and refer to
Disassembly and Assembly, Gear Group (Front)
- Install.
Note: Ensure that the fuel injection pump is in the
unlocked position after the installation of the fuel
injection pump gear is completed.

Illustration 11

g01350306

Typical example

2. Use Tooling (D) in order to lubricate O-ring seal

(10). Install a new O-ring seal (10) onto the fuel
injection pump (4).
3. Install the new washers (9) to bolts (8).
4. Align the holes in the fuel injection pump with the
holes in the front housing. Install the fuel injection
pump (4) to the housing.
Note: The fuel injection pump should be supported
by hand until the bolts are installed.

KENR6247

11
Disassembly and Assembly Section

i02744530

Fuel Injection Pump Gear Remove

Removal Procedure
Table 3

Required Tools
Tool

Part
Number

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

Puller (Three Leg)

A2

Illustration 12

g01350305

Typical example

12. Remove the plugs and caps from ports and tube
assemblies.
13. Install the fuel injection lines. Refer to
Disassembly and Assembly, Fuel Injection Lines
- Install.
14. Connect plastic tube assemblies (1) and (6) to
fuel injection pump(4).
15. Connect tube assembly (3) to fuel injection pump
(4).
16. Install tube assembly (2).
17. Connect the harness assembly to solenoid (7).
Tighten nut (7) to a torque of 4 Nm (35 lb in).
18. Connect the harness assembly to solenoid (5).
19. Restore the fuel supply.
20. Restore the electrical supply.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.

Part Name

Qty

Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Care must be taken in order to ensure that
the fuel injection pump timing is not lost during the
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.
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.

12
Disassembly and Assembly Section

KENR6247

4. Apply sufficient pressure to fuel injection pump

gear (3) in a counterclockwise direction in order to
remove the backlash. Lock fuel injection pump (4)
in this position. Loosen locking screw (5). Rotate
spacer (6) in order to allow locking screw (5) to
tighten against the shaft of the fuel injection pump.
Tighten locking screw (5) to a torque of 17 Nm
(13 lb ft).
Note: Locking screw (5) must be tightened in order
to prevent the shaft of the fuel injection pump from
rotating. The shaft of the fuel injection pump must
not be rotated after the fuel injection pump has been
removed from the engine.

Illustration 13

g01343056

Typical example

2. Install Tooling (B) through hole (X) in camshaft

gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position.
3. Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in
the correct position.
Note: Do not use excessive force to install Tooling
(C). Do not use Tooling (C) to hold the crankshaft
during repairs.

Illustration 15

g01335384

Alignment of timing marks

5. Mark gears (1), (2) and (3) in order to show

alignment. Refer to Illustration 15.
Note: Identification will ensure that the gears can be
installed in the original alignment.

Illustration 16

g01335385

6. Loosen nut (8) on fuel pump gear (3).

Illustration 14

g01320304

7. Install Tooling (D) through two opposite holes in

fuel pump gear (3). Tighten Tooling (D) until the
fuel pump gear is released.
8. Remove Tooling (D) from fuel pump gear (3).

KENR6247

13
Disassembly and Assembly Section

9. Remove nut (8) and the washer from fuel pump

gear (3). Remove the fuel pump gear.
i02744534

Fuel Injection Pump Gear Install

Installation Procedure
Table 4

Required Tools

Illustration 17
Typical example

Tool

Part
Number

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

A2

Part Name

Qty

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

21825617

Dial Indicator Group

Finger Clock

g01343058

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

2. Ensure that Tooling (C) is installed in hole (Y) in

the front housing. Use Tooling (C) in order to lock
the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling
(C). Do not use Tooling (C) to hold the crankshaft
during repairs.
3. Ensure that Tooling (B) is installed into hole (X) in
camshaft gear (1).
4. Ensure that shaft (9) on the fuel injection pump is
clean, dry and free from damage.
5. Ensure that the fuel injection pump is locked in
the correct position. Refer to Disassembly and
Assembly, Fuel Injection Pump - Install.
6. Ensure that the fuel pump gear is clean, dry and
free from wear or damage. If necessary, replace
the fuel pump gear.

Dispose of all fluids according to local regulations and

mandates.
Note: The fuel injection pump must remain locked
until the procedure instructs you to unlock the fuel
injection pump.
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.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.

Illustration 18

g01335384

Alignment of timing marks

7. Install fuel pump gear (3) to shaft (9) of the fuel

injection pump. Ensure that the timing marks on
gears (2) and (3) are in alignment and that the
mesh of the gears is correct.

14
Disassembly and Assembly Section

KENR6247

10. Tighten nut (8) to a torque of 88 Nm (65 lb ft).

11. Use Tooling (D) to measure the backlash of gears
(2) and (3). Ensure that the backlash for the gears
is within specified values. Refer to Specifications,
Gear Group (Front) for further information.
12. Lubricate the teeth of the gears with clean engine
oil.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
Illustration 19

g01343060
i02628874

Typical example

Fuel Injector - Remove

Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, Fuel Injection Lines
- Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 20

g01320629

Typical example

8. Install a new spring washer (10) and install nut

(8) to shaft (9) of the fuel injection pump. Apply
sufficient pressure to the fuel injection pump gear
(3) in a counterclockwise direction in order to
remove the backlash. Tighten nut (8) to a torque
of 24 Nm (17 lb ft). Unlock the fuel injection pump
(5).
In order to unlock the fuel injection pump, loosen
locking screw (6) on the fuel injection pump.
Rotate spacer (7) in order to allow locking screw
(6) to tighten against the spacer. Tighten the
locking screw against the spacer to a torque of
17 Nm (13 lb ft). This will prevent the locking
screw from tightening against the shaft of the fuel
injection pump.
9. Remove Tooling (B) and (C).

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Put identification marks on all plastic tube
assemblies for installation purposes. Plug all plastic
tube assemblies and tube assemblies. This helps to
prevent fluid loss and this helps to keep contaminants
from entering the system.
1. Isolate the fuel supply.

KENR6247

Illustration 21

15
Disassembly and Assembly Section

g01320676

Typical example

2. Remove fuel return lines (2) from fuel injector (1).

3. Remove bolt (3). Remove clamp (4) from fuel
injector (1).

Illustration 22

g01320782

1. Ensure that the seat for the fuel injector in the

cylinder head is clean and free from damage.
Position a new sealing washer (6) on the seat for
the fuel injector in the cylinder head.
2. Install a new O-ring seal (5) on fuel injector (1).

4. Remove fuel injector (1) from the cylinder head.

Remove O-ring seal (5) from fuel injector (1).

3. Install fuel injector (1) into the cylinder head.

5. Remove seat washer (6).

Note: Alignment Pin (7) must be located opposite

clamp (4).
i02628873

Fuel Injector - Install

4. Position clamp (4) on fuel injector (1). Install bolt

(3). Tighten the bolt to a torque of 27 Nm (20 lb ft).
5. Install fuel return lines (2) to fuel injector (1).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection Lines - Install.
i02628909

Turbocharger - Remove
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

16
Disassembly and Assembly Section

KENR6247

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Plug and cap all open ports and tube
assemblies.
1. If the turbocharger is equipped with an exhaust
elbow, remove the exhaust elbow. Refer to
Disassembly and Assembly, Exhaust Elbow Remove and Install.
2. Loosen the hose clamp and disconnect the air
inlet hose from the turbocharger.
3. Loosen the hose clamp and disconnect the air
outlet hose from the turbocharger. If the engine is
equipped with an air pipe, remove the air pipe and
remove the gasket from the cylinder head.
4. If the valve mechanism cover is equipped with a
heat shield, remove the heat shield.

Illustration 23

g01343533

Typical example

5. If the turbocharger is equipped with an adapter

(9), Remove nuts (10) and remove adapter (9)
from turbocharger (5). Remove gasket (11) (not
shown).
6. Remove banjo bolt (1) and disconnect tube
assembly (3) from turbocharger (5). Remove
sealing washers (2) from tube assembly (3).
7. Remove banjo bolt (4) and disconnect tube
assembly (3) from the cylinder block. Remove
sealing washers (2) from tube assembly (3).
Remove tube assembly (3).
8. Remove bolts (13). Disconnect tube assembly
(14) from turbocharger (5). Remove joint (12).

KENR6247

17
Disassembly and Assembly Section

If necessary, remove bolts (15) and remove tube

assembly (14) from the cylinder block. Remove
joint (16).
If tube assembly (14) is secured with tube clips,
loosen the fasteners for the tube clips. If the
engine has a top mounted turbocharger, the
exhaust manifold must be removed in order to
remove tube assembly (13). Refer to Disassembly
and Assembly , Exhaust Manifold - Remove and
Install.
9. Remove nuts (8) and remove turbocharger (5).
Note: Do not use the actuator rod to lift the
turbocharger.
10. Remove gasket (7).
11. If necessary, remove the studs from the exhaust
manifold.
i02628908

Turbocharger - Install
Installation Procedure
Table 5

Required Tools
Tool

Part Number

Part Description

Qty

21820117

POWERPART
Threadlock and Nutlock

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the turbocharger is clean and free
from damage. Inspect the turbocharger for
wear. Refer to Systems Operation, Testing and
Adjusting, Turbocharger - Inspect for more
information. If the turbocharger is worn, the
complete turbocharger must be replaced.

Illustration 24

g01343533

Typical example

2. Test actuator (6) for correct operation. Refer

to Systems Operation, Testing and Adjusting,
Turbocharger - Inspect. If the actuator is
damaged or the actuator does not operate within
the specified limits, the complete turbocharger
must be replaced.
3. Clean the mating surfaces of the exhaust manifold.
If necessary, install the studs to the exhaust
manifold. Tighten the studs to a torque of 18 Nm
(13 lb ft).
4. Install a new gasket (7) to the exhaust manifold.
5. Position turbocharger (5) onto the exhaust
manifold and install nuts (8). Tighten the nuts to a
torque of 44 Nm (32 lb ft).

18
Disassembly and Assembly Section

Note: Do not use the actuator rod to lift the

turbocharger.
6. Position a new joint (12) and tube assembly (14)
onto turbocharger (5). Install bolts (13) finger tight.
7. The turbocharger has different sized bolts (13).
Tighten M6 bolts to a torque of 9 Nm (80 lb in).
Tighten M8 bolts to a torque of 22 Nm (16 lb ft).
8. Position a new joint (16) onto the cylinder block.
Install bolts (15) finger tight.
9. Tighten bolts (15) to a torque of 22 Nm (16 lb ft).
If tube assembly (14) is secured with tube clips,
tighten the fasteners for the tube clips to a torque
of 22 Nm (16 lb ft).
10. Lubricate the bearings of turbocharger (5) with
clean engine oil through the oil inlet port. Rotate
the shaft of the turbocharger in order to distribute
the lubricant.
11. Position tube assembly (3) onto turbocharger (5).
Install new washers (2) and banjo bolt (1) to tube
assembly (3). Tighten the banjo bolt finger tight.

KENR6247

Note: If the air outlet hose has a reflective heat

shield, ensure that the reflective heat shield is
installed toward the engine.
17. Connect the air inlet hose to turbocharger (5).
18. If the valve mechanism cover is equipped with
a heat shield, install the heat shield. Tighten the
fasteners for the heat shield to a torque of 9 Nm
(80 lb in).
i02628843

Exhaust Manifold - Remove

and Install
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly
and Assembly, Turbocharger - Remove.

12. Install new washers (2) and banjo bolt (4) onto
tube assembly (3). Connect the tube assembly to
the cylinder block. Tighten the banjo bolt finger
tight.
13. Tighten banjo bolts (1) and (4) to a torque of
20 Nm (15 lb ft).
Note: Ensure that the tube assembly does not come
into contact with any other engine components.
14. The turbocharger is equipped with a adapter (9).
Install a new gasket (11) (not shown) and position
the adapter (9) onto the turbocharger. Install
nuts (10). Tighten the nuts to a torque of 44 Nm
(33 lb ft).
15. If the turbocharger is equipped with an exhaust
elbow, install the exhaust elbow. Refer to
Disassembly and Assembly, Exhaust Elbow Remove and Install.
16. Connect the air outlet hose to turbocharger (5).
If the engine is equipped with an air pipe, install
the air pipe and install the gasket to the cylinder
head. Apply Tooling (A) to the fasteners for the air
pipe. Tighten the fasteners to a torque of 22 Nm
(16 lb ft).
Tighten the hose clamps to a torque of 5 Nm
(44 lb in).

Illustration 25
Typical example

g01343539

KENR6247

19
Disassembly and Assembly Section

g01363916

Illustration 26
Sequence for loosening the exhaust manifold

1. Loosen bolts (4) in reverse numerical order to the

sequence that is shown in Illustration 26.
Note: This will help prevent distortion of the exhaust
manifold.
2. Remove bolts (4) from exhaust manifold (3).

Illustration 27

g01343539

Typical example

1. Ensure that the exhaust manifold is clean and free

from damage. Clean the joint face of the cylinder
head.

Note: Bolts (4) may be equipped with spacers.

Record the position of the spacers. Support the
manifold as the bolts are removed.

2. If necessary, install studs (2) to exhaust manifold

(3). Tighten the studs to a torque of 18 Nm
(13 lb ft).

3. Remove exhaust manifold (3).

4. Remove exhaust manifold gasket (1).
5. If necessary, remove studs (2) from exhaust
manifold (3).

Installation Procedure
Table 6

Required Tools
Tool

Part
Number

Part Description
Guide Bolt
(M10 by 100 mm)

Qty
2
Illustration 28

g01363918

Tightening sequence for the exhaust manifold

3. Install Tooling (A) to the cylinder head in positions

(X). Refer to Illustration 28.
4. Position a new exhaust manifold gasket (1) onto
Tooling (A).
Note: Ensure that the exhaust manifold gasket is
correctly oriented.
5. Align exhaust manifold (3) with Tooling (A). Install
the exhaust manifold to the cylinder head.

20
Disassembly and Assembly Section

KENR6247

Note: If the engine has a top mounted turbocharger,

the tube assembly for the oil drain must be connected
to the cylinder block before the exhaust manifold is
installed.

Installation Procedure

6. Install new bolts (4) finger tight.

Note: Bolts (4) that were equipped with spacers.
Install the spacer in the original position.
7. Remove Tooling (A). Install the remaining bolts
(4) finger tight.
8. Tighten bolts (4) to a torque of 40 Nm (30 lb ft) in
the sequence that is shown in Illustration 28.
End By:
a. Install the turbocharger. Refer to Disassembly and
Assembly, Turbocharger - Install.
i02628842

Exhaust Elbow - Remove and

Install

Illustration 30

g01343547

Typical example

1. Ensure that the exhaust elbow is clean and free

from wear or damage.
2. Position support bracket (3) to the cylinder block
and install bolts (5). Tighten bolts (5) to a torque of
44 Nm (33 lb ft).

Removal Procedure

3. Position exhaust elbow (2).

Note: Ensure the correct orientation of the exhaust
elbow.
4. Install bolts (4) to support bracket (3). Tighten
bolts (4) to a torque of 44 Nm (33 lb ft).

Illustration 29

g01343547

Typical example

1. Remove bolts (4) and remove exhaust elbow (2).

Note the orientation of the exhaust elbow.
2. Remove bolts (5) and remove support bracket (3)
from the cylinder block.

KENR6247

21
Disassembly and Assembly Section

i02628893

Inlet and Exhaust Valve

Springs - Remove and Install

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Removal Procedure

Follow the recommended procedure and use all

recommended tooling to release the spring force.

Table 7

Required Tools
Tool

Part
Number

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

21825739

Valve Spring Compressor

27610235

Adapter

27610295

Head

A2

Part Description

Qty

Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: The following procedure should be adopted in
order to remove the valve springs when the cylinder
head is installed to the engine. Refer to Disassembly
and Assembly, Inlet and Exhaust Valves - Remove
and Install for the procedure to remove the valve
springs from a cylinder head that has been removed
from the engine.
Note: Ensure that the appropriate piston is at the top
center position before the valve spring is removed.
Failure to ensure that the piston is at the top center
position may allow the valve to drop into the cylinder
bore.
NOTICE
Plug the apertures for the push rods in the cylinder
head in order to prevent the entry of loose parts into
the engine.

NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
1. Follow Steps 1.a through 1.d in order to position
the appropriate piston at top center.
a. Install Tooling (B) in position on the cylinder
head in order to compress a valve spring for
the appropriate piston.
b. Use Tooling (B) in order to compress valve
spring (3) and open the valve slightly.
Note: Do not compress the spring so that the valve
spring retainer (2) touches the valve stem seal.
c. Use Tooling (A) in order to rotate the crankshaft
carefully, until the piston touches the valve.
Note: Do not use excessive force to turn the
crankshaft. The use of force can result in bent valve
stems.
d. Continue to rotate the crankshaft and gradually
release the pressure on Tooling (B) until the
piston is at the top center position. The valve
is now held in a position that allows the valve
spring to be safely removed.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Note: Valve springs must be replaced in pairs for the
inlet valve or the exhaust valve of each cylinder. If all
valve springs require replacement the procedure can
be carried out on two cylinders at the same time. The
procedure can be carried out on the following pairs of
cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one
pair of cylinders to another pair of cylinders.

22
Disassembly and Assembly Section

KENR6247

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
1. Inspect the valve springs for the correct length.
Refer to Specifications, Cylinder Head Valves
for more information.
2. If necessary, install a new valve stem seal onto
the valve guide.
g01343550

Illustration 31
Typical example

Note: The outer face of the valve guide must be

clean and dry before installing the valve stem seal.

2. Apply sufficient pressure to Tooling (B) in order to

allow removal of the valve keepers (1). Remove
valve keepers (1).
Note: Do not compress the spring so that the valve
spring retainer (2) touches the valve stem seal.
3. Slowly release the pressure on Tooling (B).
4. Remove valve spring retainer (2) and remove
valve spring (3).
5. If necessary, remove the valve stem seals.
6. Repeat Steps 2 through 5 in order to remove
the remaining valve spring from the appropriate
cylinder.
7. Remove Tooling (B).

Installation Procedure

Illustration 32
Typical example

Table 8

Required Tools
Tool

Part
Number

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

21825739

Valve Spring Compressor

27610235

Adapter

27610295

Head

A2

g01343550

Part Description

Qty

3. Install valve spring (3) onto the cylinder head.

Position valve spring retainer (2) onto valve spring
(3).

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.

KENR6247

23
Disassembly and Assembly Section

4. Install Tooling (B) in the appropriate position on

the cylinder head in order to compress the valve
spring.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
5. Apply sufficient pressure to Tooling (B) in order to
install valve keepers (1). Install the valve spring
keepers (1).
Note: Do not compress the spring so that valve
spring retainer (2) touches the valve stem seal .
6. Carefully release the pressure on Tooling (B).
Note: Ensure that the valve keepers are correctly
seated.
7. Repeat Steps 2 to 6 for the remaining valves.

The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.

Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Clean the bottom face of the cylinder head.
Check the depth of the valves below the face of
the cylinder head before the valve springs are
removed. Refer to Specifications, Cylinder Head
Valves for the correct dimensions.
2. Place a temporary identification mark on the
heads of the valves in order to identify the correct
position. Inlet valves have a recess in the center
of the head.
Note: Do not stamp the heads of the valve. Stamping
or punching the heads of the valves could cause the
valves to fracture.
3. Use a suitable lifting device to position the cylinder
head with the valve springs upward. The weight of
the cylinder head is approximately 56 kg (125 lb).
Note: Ensure that the cylinder head is kept on a
clean, soft surface in order to prevent damage to the
machined face.

8. Remove Tooling (B).

End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Install.
i02628894

Inlet and Exhaust Valves Remove and Install

Removal Procedure
Table 9

Required Tools
Tool

Part
Number

Part Description

Qty

21825739

Valve Spring Compressor

27610235

Adapter

27610295

Head

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

24
Disassembly and Assembly Section

KENR6247

6. Slowly release the pressure on Tooling (A).

7. Remove valve spring retainer (2). Remove valve
spring (3).
8. Repeat Steps 4 to 7 for the remaining valves.
9. Remove Tooling (A).
10. Remove valve stem seals (4).
11. Use a suitable lifting device to carefully turn over
the cylinder head.
12. Remove valves (5).

Installation Procedure
Table 10

Required Tools
Illustration 33

g01343550

Typical example

4. Install Tooling (A) in position on the cylinder head

in order to compress the appropriate valve spring.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.

Tool

Part
Number

Part Description

Qty

21825739

Valve Spring Compressor

27610235

Adapter

27610295

Head

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Clean all components of the cylinder head
assembly. Ensure that all ports, all coolant
passages and all lubrication passages in the
cylinder head are free from debris. Follow Steps
1.a through 1.e in order to inspect the components
of the cylinder head assembly. Replace any
components that are worn or damaged.
a. Inspect the cylinder head for wear and for
damage. Refer to Systems Operation, Testing
and Adjusting, Cylinder Head Inspect.
b. Inspect the valve seats for wear and for
damage. Refer to Specifications, Cylinder
Head Valves for further information.

Illustration 34

g01352229

Typical example

5. Apply sufficient pressure to Tooling (A) in order to

remove valve keepers (1).
Note: Do not compress the spring so that valve
spring retainer (2) touches valve stem seal (4).

c. Inspect the valve guides for wear and for

damage. Refer to Specifications, Cylinder
Head Valves and Systems Operation, Testing
and Adjusting, Valve Guide - Inspect for
further information.
d. Inspect the valves for wear and for damage.
Refer to Specifications, Cylinder Head Valves.

KENR6247

25
Disassembly and Assembly Section

e. Inspect the valve springs for the correct length.

Refer to Specifications, Cylinder Head Valves.

Illustration 36
Illustration 35

g01352229

g01343550

Typical example

6. Install Tooling (A) in the appropriate position on

the cylinder head in order to compress valve
spring (3).

2. Lubricate the stems of valves (5) with clean engine

oil. Install valves (5) in the appropriate positions in
the cylinder head. Check the depth of the valves
below the face of the cylinder head. Refer to
Systems Operation, Testing and Adjusting, Valve
Depth - Inspect for more information.

NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.

3. Use a suitable lifting device to carefully turn over

the cylinder head. The weight of the cylinder head
is approximately 56 kg (125 lb).

7. Apply sufficient pressure to Tooling (A) in order to

install valve keepers (1).

Note: Ensure that all of the valves remain in place.

Note: Do not compress the spring so that valve

spring retainer (2) touches valve stem seal (4).

4. Install new valve stem seals (4) onto each of the

valve guides.
Note: The outer face of the valve guides must be
clean and dry before installing the valve stem seals.
5. Install valve spring (3) onto the cylinder head.
Position valve spring retainer (2) onto valve spring
(3).

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
8. Carefully release the pressure on Tooling (A).
9. Repeat Steps 5 to 8 for the remaining valves.
10. Remove Tooling (A) from the cylinder head.
11. Use a suitable lifting device to position the cylinder
head on a support. Ensure that the heads of the
valves are not obstructed. Lightly strike the top of
the valves with a soft hammer in order to ensure
that valve keepers (1) are properly installed.

26
Disassembly and Assembly Section

KENR6247

End By:
a. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02628834

Engine Oil Filter Base Remove and Install

1. Use Tooling (A) to remove engine oil filter (3).

Refer to Operation and Maintenance Manual,
Engine Oil and Filter - Change.
2. If the engine oil pressure sensor is located in
the engine oil filter base, remove the engine
oil pressure sensor. Refer to Disassembly and
Assembly, Engine Oil Pressure Sensor - Remove
and Install.
3. Remove bolts (4) and remove engine oil filter base
(2).

Removal Procedure

4. Remove joint (1).

Table 11

5. If the engine oil filter base has a spacer plate,

remove the spacer plate and remove the joint.

Required Tools
Tool

Part Number

Part Description
Strap Wrench

Qty
1

Note: The oil filter may be installed vertically or the

oil filter may be installed horizontally.

6. If necessary, remove plug (6) from engine oil filter

base (2). Remove O-ring seal (5) from the plug.

Installation Procedure
Table 12

Required Tools

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, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.

Tool

Part Number

Part Description

Qty

21820117

POWERPART
Threadlock and Nutlock

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Dispose of all fluids according to local regulations and

mandates.

Illustration 38

g01343554

Typical example

1. Ensure that the engine oil filter base is clean.

Clean the mating surfaces of the cylinder block.
Illustration 37
Typical example

g01343554

2. If necessary, install a new O-ring seal (5) to plug

(6). Install plug (6) to engine oil filter base (2).
Tighten the plug to a torque of 12 Nm (106 lb in).

KENR6247

27
Disassembly and Assembly Section

3. Install bolts (4) to engine oil filter base (2).

4. Install a new joint (1) onto bolts (4). If the engine
oil filter base has a spacer plate, install the spacer
plate and a new joint onto the bolts.

3. If necessary, remove the electric starting motor.

Refer to Disassembly and Assembly, Electric
Starting Motor - Remove and Install.

5. Apply Tooling (B) to the threads of the bolts. Install

the assembly of the engine oil filter base to the
cylinder block.
6. Tighten bolts (4) to a torque of 22 Nm (16 lb ft).
7. If the engine oil pressure sensor is located in
the engine oil filter base, Install the engine oil
pressure sensor. Refer to Disassembly and
Assembly, Engine Oil Pressure Sensor - Remove
and Install.
8. Install a new engine oil filter (3). If necessary,
fill the engine oil pan to the correct level that is
indicated on the oil level gauge. Refer to Operation
and Maintenance Manual, Engine Oil Level Check.
i02628833

Engine Oil Cooler - Remove

Illustration 39

g01343557

Typical example

Removal Procedure
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant from the cooling system into
a suitable container. Refer to Operation and
Maintenance Manual, Cooling System Coolant Change for the correct procedure.
2. Drain the engine lubricating oil into a suitable
container. Refer to Operation and Maintenance
Manual, Engine Oil and Filter - Change for the
correct procedure.

Illustration 40

g01343558

Tightening sequence for the engine oil cooler

4. Loosen fasteners (7) in reverse numerical order

to the sequence that is shown in Illustration 40.
Remove fasteners (7). Support the assembly
of the engine oil cooler (1) as the fasteners are
removed.
Note: fasteners (7) are different lengths. Note the
correct position of the fasteners. Note the position of
any brackets that are secured by the fasteners. Do
not remove fasteners (6) at this time.

28
Disassembly and Assembly Section

KENR6247

5. Remove the assembly of oil cooler (1) from the

cylinder block.

b. Position new joints (4) onto housing (5). Install

cooler matrix (3).

6. Remove joint (2).

c. Apply Tooling (A) to the threads of bolts (6).

7. Follow Steps 7.a through 7.c in order to

disassemble the engine oil cooler.

d. Install bolts (6). Tighten the bolts to a torque of

22 Nm (16 lb ft).
2. Clean the mating surface of the cylinder block.

a. Remove bolts (6).

b. Remove cooler matrix (3) from housing (5).
c. Remove joints (4).
i02628832

Engine Oil Cooler - Install

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 42

g01347870

Typical example

3. Position a new joint (2) on the assembly of engine

oil cooler (1). Install fasteners (7) to positions (X)
on the assembly of engine oil cooler (1).
Note: The holes in the joint have serrations that hold
the fasteners captive.
4. Install the assembly of engine oil cooler (1) to the
cylinder block. Tighten bolts (7) finger tight.
Note: The fasteners are different lengths. Ensure
that the different fasteners are installed in the correct
location. Ensure that any brackets that are secured
by the fasteners are installed in the correct location.

Illustration 41

g01347869

Typical example

1. Follow Steps 1.a through 1.d in order to assemble

the engine oil cooler.
a. Ensure that cooler matrix (3) is clean and free
from damage. Ensure that housing (5) is clean
and free from damage.

5. Apply Tooling (B) to the fasteners (7) at positions

(Y).
Note: The fasteners in this position are allen head
screws.

KENR6247

29
Disassembly and Assembly Section

Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
g01343558

Illustration 43
Tightening sequence for the engine oil cooler

Follow the recommended procedure and use all

recommended tooling to release the spring force.

6. Install the remaining fasteners (7) into the engine

oil cooler (1). Tighten the fasteners to a torque of
22 Nm (16 lb ft). Tighten the bolts in the sequence
that is shown in Illustration 43.
7. If necessary, Install the electric starting motor.
Refer to Disassembly and Assembly, Electric
Starting Motor - Remove and Install.
8. Fill the cooling system to the correct level.
Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
procedure.
9. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, Engine Oil
Filter and Change for the correct procedure.
i02628841

Engine Oil Relief Valve Remove and Install

(Engines Without a Balancer
Unit)

Table 13

Part Description
Telescopic Magnet

Typical example

1. Remove bolts (6) and suction pipe (7).

2. Remove the joint from suction pipe (5) (not
shown).

Note: The spring force will be released when the cap

is removed.

Required Tools
Part
Number

g01343561

3. Loosen cap (2). Carefully remove cap (2) from the

housing of engine oil pump (1).

Removal Procedure

Tool

Illustration 44

Qty
1

4. Remove spring (4) from the bore for the relief

valve in the housing of engine oil pump (1).

30
Disassembly and Assembly Section

KENR6247

5. Use Tooling (A) to remove plunger (3) from the

bore for the relief valve in the housing of engine
oil pump (1).

Installation Procedure

Note: The plunger must slide freely in the bore for

the relief valve.

Table 14

Required Tools
Tool

Part
Number

Part Description
Loctite 577

2. Lubricate plunger (3) with clean engine oil. Use

long nose pliers to install plunger (3) and spring
(4) into the bore for the relief valve in the housing
of engine oil pump (1).

Qty
1

3. Apply Tooling (A) to the threads of cap (2). Install

cap (2) to engine oil pump (1). Tighten the cap to
a torque of 35 Nm (26 lb ft).

NOTICE
Keep all parts clean from contaminants.

Note: Ensure that the spring is properly located

inside the plunger and the cap. Ensure that Tooling
(A) does not contaminate the bore for the relief valve
in the housing of engine oil pump.

Contaminants may cause rapid wear and shortened

component life.

4. Install suction pipe (7) and a new joint (5) to the

assembly of the engine oil pump.
5. Install bolts (6). Tighten the bolts to a torque to
22 Nm (16 lb ft).
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
i02628840

Engine Oil Relief Valve Remove and Install

(Engines with a Balancer Unit)
Removal Procedure
Illustration 45

g01343561

Table 15

Required Tools

Typical example

1. Ensure that all components are clean and free

from wear or damage. If necessary, replace any
components that are worn or damaged. If the
bore for the relief valve in the housing of engine
oil pump (1) is worn or damaged, the complete
assembly of the engine oil pump must be replaced.

Tool

Part
Number

Part Description
Telescopic Magnet

Qty
1

Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly , Engine Oil Pan - Remove and
Install.

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

31
Disassembly and Assembly Section

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

Illustration 47

g01343600

Typical example

1. Ensure that all components are clean and free

from wear or damage. If necessary, replace any
components that are worn or damaged. If the
bore for the relief valve in balancer (1) is worn or
damaged, the complete assembly of the balancer
must be replaced.
g01343600

Illustration 46
Typical example

1. Loosen cap (2). Carefully remove the cap from

balancer (1).
Note: The spring force will be released when the cap
is removed.
2. Remove spring (3) from the bore for the relief
valve in balancer (1).
3. Use Tooling (A) in order to remove plunger (4)
from the bore for the relief valve in balancer (1).

Installation Procedure
Required Tools
Part
Number

Part Description
Loctite 577

To prevent possible injury, follow the established

assembly procedure and wear protective equipment.
2. Lubricate plunger (4) with clean engine oil. Install
plunger (4) and spring (3) into the bore for the
relief valve in balancer (1).
Note: The plunger must slide freely in the bore for
the relief valve.
3. Apply Tooling (B) to the threads of cap (2). Install
cap (2) to balancer (1). Tighten the cap to a torque
of 21 Nm (15.5 lb ft).

Table 16

Tool

Improper assembly of parts that are spring loaded

can cause bodily injury.

Qty
1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Note: Ensure that the spring is properly located

inside the plunger and the cap. Ensure that Tooling
(B) does not contaminate the bore for the relief valve
in balancer (1).
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.

32
Disassembly and Assembly Section

KENR6247

i02628837

Engine Oil Pump - Remove and

Install
(Engines Without a Balancer
Unit)
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
Note: This procedure is for the removal of the engine
oil pump on engines that are not equipped with
a balancer. Refer to Disassembly and Assembly,
Balancer Group - Remove for information on the
removal of the engine oil pump for engines that are
equipped with a balancer.

Illustration 48

NOTICE
Keep all parts clean from contaminants.

2. Remove the joint from suction pipe (2).

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.

g01343631

Typical example

1. Remove bolts (1) and suction pipe (2).

3. Remove bolts (5). Remove the assembly of engine

oil pump (3) from the cylinder block.
4. If necessary, remove pressure relief valve (4)
from the housing of engine oil pump (3). Refer to
Disassembly and Assembly, Engine Oil Relief
Vave - Remove and Install.

KENR6247

33
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
If any of the parts on the engine oil pump are worn or
damaged, the entire pump must be replaced.
1. Ensure that all components of the engine oil pump
are clean and free from wear or damage. Check
the clearance between the outer rotor of the oil
pump and the oil pump body. Check the clearance
between the outer rotor and the inner rotor. Check
the end play of the rotor. Refer to the Systems
Operation,Testing and Adjusting, Engine Oil
Pump - Inspect. Replace the complete assembly
of the engine oil pump if any of the components
are worn or damaged.

g01343633

Illustration 49
Typical example

5. If necessary, remove bolts (9) and front cover

assembly (6). Remove outer rotor (7) from the
housing of engine oil pump (3).
Note: Do not remove dowels (8) and (10) from the
housing of the engine oil pump unless the dowels
are damaged.

Installation Procedure
Table 17

Required Tools
Tool
A

Part
Number
21825617
-

Part Name

Qty

Dial Indicator Group

Finger Clock

Note: This procedure is for the installation of the

engine oil pump on engines that are not equipped
with a balancer. Refer to Disassembly and Assembly,
Balancer Group - Install for information on the
installation of the engine oil pump for engines that
are equipped with a balancer.

Illustration 50

g01343633

2. If necessary, lubricate the internal components of

the assembly of the engine oil pump with clean
engine oil. Install outer rotor (7) and front cover
(6) to the housing of engine oil pump (3). Install
bolts (9). Tighten the bolts to a torque of 9.5 Nm
(84 lb in).

34
Disassembly and Assembly Section

KENR6247

i02628917

Water Pump - Remove

Removal Procedure
Start By:
a. Remove the fan and the fan pulley. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 51

g01343631

3. If necessary, install pressure relief valve (4). Refer

to Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install for further information.
4. Ensure that dowels (8) and (10) are correctly
located in the housing of the engine oil pump (3).
Position the assembly of the engine oil pump onto
the cylinder block.
Note: Ensure that the dowels in the housing of the
engine oil pump are aligned with the holes in the
cylinder block.
5. Install bolts (5). Tighten the bolts to a torque of
44 Nm (32 lb ft).
6. Install suction pipe (2) and a new joint to the
assembly of the engine oil pump.
7. Install bolts (1). Tighten the bolts to a torque to
22 Nm (16 lb ft).
8. Use Tooling (A) in order to check the backlash
between the idler gear of the oil pump and the
crankshaft gear. Refer to Specifications, Gear
Group - Front for further information.
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component 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 disposal.
Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
procedure.
2. Loosen the hose clamps and remove the hose
from the water pump inlet.

KENR6247

35
Disassembly and Assembly Section

i02628916

Water Pump - Install

Installation Procedure
Table 18

Required Tools
Tool

Part
Number

Part Description
Guide Bolt
(M8 by 80 mm)

Qty
2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the water pump is clean and free from
wear or damage. If necessary, replace the water
pump.
Illustration 52

g01263054

Typical example

3. Remove bolts (4). The bolts are different lengths.

Note the positions of the different bolts.
Note: Do not remove bolts (7) at this time.
4. Remove water pump (3) from front cover (1).
Note: If necessary, tap the water pump with a soft
hammer in order to loosen the water pump.
5. Remove joint (2).
6. If necessary, remove the cover (6) from the water
pump. Follow Steps 6.a through 6.c in order to
remove the cover.
a. Remove bolts (7).
b. Remove cover (6).
c. Remove joint (5).

Illustration 53

g01269391

Typical example

2. If necessary, install cover (6) to water pump (3).

Follow Steps 2.a through 2.d in order to install
the cover.
a. Clean the mating surface of cover (6).

36
Disassembly and Assembly Section

KENR6247

b. Position a new joint (5) onto water pump (3).

c. Install cover (6) to water pump (3).
d. Install bolts (7) to cover (6). Tighten the bolts
finger tight.
3. Clean the mating surface of front cover (1).

Illustration 55

g01269393

Tightening sequence for the water pump

9. Tighten bolts (4) and bolts (7) to a torque of 22 Nm

(16 lb ft). Refer to Illustration 53. Tighten the bolts
in the sequence that is shown in Illustration 55.
Illustration 54

g01269392

4. Install Tooling (A) in position (X).

5. Use Tooling (A) in order to align a new joint (2) to
front cover (1). Install the joint to the front cover.
6. Align water pump (3) with Tooling (A). Install the
water pump to front cover (1).
Note: Ensure that the gear of the water pump and
the gear of the fuel injection pump mesh.
7. Install bolts (4). Refer to Illustration 53. Tighten
the bolts finger tight.
Note: Ensure that bolts of different lengths are
installed in the correct positions.
8. Remove Tooling (A) and install remaining bolts
(4) finger tight.

10. Install the hose to the water pump inlet. Tighten

the hose clamps.
11. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, Cooling
System Coolant - Change for the correct
procedure.
End By:
a. Install the fan and the fan pulley. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
i02628918

Water Temperature Regulator Remove and Install

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

37
Disassembly and Assembly Section

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant from the cooling system to a
level below the water temperature regulator, into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
draining procedure.
2. Loosen the hose clamps from the upper radiator
hose and disconnect the upper radiator hose from
water temperature regulator housing (2).

g01343959

Illustration 57
Typical example

5. Remove O-ring seal (3) from water temperature

regulator housing (2).

Installation Procedure
Table 19

Required Tools
Tool

Part
Number

21820221

Part Description
POWERPART
Rubber Grease

Qty
1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 56

g01343959

Typical example

3. Remove bolts (1) from water temperature

regulator housing (2).
4. Remove water temperature regulator housing (2)
from the cylinder head.
Note: Note the orientation of the water temperature
regulator housing.

1. Ensure that all components of water temperature

regulator are clean and free of wear or damage.
Check the water temperature regulator for correct
operation. Refer to Systems Operation, Testing
and Adjusting, Water Temperature Regulator
- Test for the procedure to test the water
temperature regulator. If any components of the
water temperature regulator are worn or damaged,
the complete assembly must be replaced.

38
Disassembly and Assembly Section

Illustration 58

KENR6247

g01343960

g01343959

Illustration 59

Typical example

Typical example

2. If the original water temperature regulator housing

is installed, position a new O-ring seal (3) into the
groove in water temperature regulator housing (2).

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

22 Nm (16 lb ft).

A new water temperature regulator housing is

supplied with a new O-ring seal.
3. Use Tooling (A) to lubricate the new O-ring seal.
4. Install water temperature regulator housing (2) to
the cylinder head.
Note: Ensure the correct orientation of the water
temperature regulator housing.

6. Connect the upper radiator hose and tighten the

hose clamps.
7. Fill the cooling system to the correct level.
Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
procedure.
i02628847

Flywheel - Remove
Removal Procedure
Table 20

Required Tools
Tool

Part
Number

Part Description

Qty

Guide Bolt
(1/2 inch - UNF by 4
inch)

Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.

KENR6247

39
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.

6. Inspect flywheel (1) and ring gear (3) for wear or

damage. Replace any components that are worn
or damaged.

Contaminants may cause rapid wear and shortened

component life.

7. To remove the flywheel ring gear, follow Steps 7.a

and 7.b.
a. Place the flywheel assembly on a suitable
support.
Note: Identify the orientation of the teeth on the
flywheel ring gear.
b. Use a hammer and a punch in order to remove
ring gear (3) from flywheel (1).
i02628846

Flywheel - Install
Installation Procedure
Table 21

Required Tools
Illustration 60

g01245126

Typical example

1. Remove two bolts from positions (X) on flywheel

(1).
2. Install Tooling (A) to positions (X) on flywheel (1).
3. Attach a suitable lifting device to flywheel (1).
Support the weight of the flywheel. The weight of
the flywheel is approximately 71 kg (155 lb).

Tool

Part
Number

Part Description
Guide Bolt
(1/2 inch - 20 UNF by
4 inch)

Qty
2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

4. Remove remaining bolts (2).

5. Use the lifting device in order to remove the
flywheel from the engine.

Illustration 62

g01343963

Typical example

Illustration 61
Typical example

g01245152

Always wear protective gloves when handling

parts that have been heated.

40
Disassembly and Assembly Section

KENR6247

1. If the flywheel ring gear was removed, follow

Steps 1.a through 1.c in order to install a new ring
gear to the flywheel.
a. Identify the orientation of teeth (4) on the new
ring gear (4).
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.
b. Heat flywheel ring gear (3) in an oven to a
maximum temperature of 250 C (482 F) prior
to installation.
Note: Do not use a torch to heat the ring gear.
c. Ensure that the orientation of ring gear (3) is
correct and quickly install the ring gear onto
flywheel (1).
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.

7. Remove Tooling (A) and install remaining bolts

(2) to the flywheel (1).
8. Remove the lifting device from flywheel (1).
9. Use a suitable tool to prevent the flywheel from
rotating. Tighten bolts (2) to a torque of 115 Nm
(85 lb ft).
10. Check the run out of the flywheel. Refer to
System Operation, Test and Adjusting, Flywheel Inspect for further information.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
i02628827

Crankshaft Rear Seal - Remove

Removal Procedure
Table 22

Required Tools
Tool

Part
Number

Part Description
E12 Torx Socket

Qty
1

Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 63

g01245126

Typical example

3. Install a suitable lifting device to flywheel (1). The

flywheel weighs approximately 71 kg (155 lb).
4. Install Tooling (A) to positions (X) on the
crankshaft.
5. Use the lifting device in order to position flywheel
(1) onto Tooling (A).
6. Install bolts (2) to flywheel (1) finger tight.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.

KENR6247

41
Disassembly and Assembly Section

Note: The crankshaft rear seal and the housing

are manufactured as a one-piece assembly. The
assembly is not serviceable. If the crankshaft rear
seal is removed, the assembly must be replaced.

Illustration 65

g01258105

Illustration 66

g01255709

g01269512

Illustration 64
Typical example

1. Use Tooling (A) in order to remove torx screws (1)

from crankshaft rear seal (2).
2. Remove crankshaft rear seal (2) from the cylinder
block. Discard the crankshaft rear seal.
i02628824

Crankshaft Rear Seal - Install

Typical example

Installation Procedure
Table 23

Required Tools
Tool

Part
Number

27610306

Part Description

Qty

E12 Torx Socket

Alignment Tool

1. Ensure that crankshaft flange (1) 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.
2. Ensure that the face of the cylinder block and the
bridge piece are clean and dry.

Note: The crankshaft rear seal and the housing are

manufactured as a one-piece assembly.

3. A new crankshaft rear seal is supplied with a

plastic sleeve (3). Ensure that the plastic sleeve is
squarely installed within crankshaft rear seal (2).

NOTICE
Keep all parts clean from contaminants.

Note: The plastic sleeve is included in order to

protect the lip of the seal as the seal is pushed over
the crankshaft flange.

Contaminants may cause rapid wear and shortened

component life.

Note: Do not lubricate the crankshaft rear seal or

the crankshaft flange. The crankshaft rear seal
must be installed dry.
4. Align plastic sleeve (3) with crankshaft flange (1).
Ensure that the plastic sleeve is engaged onto the
crankshaft flange. Push new crankshaft rear seal
(2) squarely onto the crankshaft flange.

42
Disassembly and Assembly Section

KENR6247

During this process, the plastic sleeve will be

forced out of the crankshaft rear seal. Discard the
plastic sleeve.
5. Align the two molded locators on crankshaft rear
seal (2) with the holes in the cylinder block. Ensure
that the crankshaft rear seal is seated against the
cylinder block.

i02628848

Flywheel Housing - Remove

and Install
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Install a suitable lifting device to the flywheel
housing in order to support the flywheel housing.
The flywheel housing weighs approximately 30 kg
(66 lb).

Illustration 67

g01258357

Tightening sequence for the crankshaft rear seal

6. Install torx screws (4) finger tight.

Note: Do not install torx screws to positions (X) at
this stage.
7. Install Tooling (B) to crankshaft rear seal (2) and
to crankshaft flange (1).
8. Use Tooling (A) in order to tighten torx screws (4)
to a torque of 22 Nm (16 lb ft). Tighten torx screws
(4) in the sequence that is shown in Illustration 67.
9. Remove Tooling (B).
10. Install remaining torx screws (4) to positions (X).
Use Tooling (A) in order to tighten the torx screws
to a torque of 22 Nm (16 lb ft). Refer to Illustration
67.

Illustration 68

g01244050

Typical example

End By:

2. Remove bolts (2) and bolts (3) from flywheel

housing (1).

a. Install the flywheel. Refer to Disassembly and

Assembly, Flywheel - Install.

3. Use the lifting device in order to remove flywheel

housing (1) from the cylinder block.

KENR6247

43
Disassembly and Assembly Section

2. Inspect crankshaft rear seal (6) for leaks. If there

are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, Crankshaft
Rear Seal - Remove and refer to Disassembly
and Assembly, Crankshaft Rear Seal - Install.
3. Clean the rear face of the cylinder block. If
necessary, install dowels (4) to the cylinder block.
4. Install Tooling (A) to the cylinder block.
5. Install dust seal (5).

g01244051

Illustration 69
Typical example

4. If the engine has an aluminum oil pan, remove

dust seal (5).
5. If necessary, remove dowels (4) from the cylinder
block.

Installation Procedure
Table 24

Required Tools
Tool

Part
Number

21825617

Part Description

Qty

Guide Stud
(M10 by 100 mm)

Dial Indicator Group

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the flywheel housing is clean and free
from damage. If necessary, replace the flywheel
housing.

Illustration 71

g01244050

Typical example

6. Install a suitable lifting device to the flywheel

housing. The flywheel housing weighs
approximately 30 kg (66 lb).
7. Use the lifting device to align flywheel housing (1)
with Tooling (A). Install the flywheel housing to the
cylinder block.
8. Install the bolts (2) and bolts (3) finger tight.
9. Remove Tooling (A). Install the remaining bolts (3).
10. Tighten bolts (3) to a torque of 63 Nm (46 lb ft).
11. Tighten bolts (2) to a torque of 75 Nm (55 lb ft).
12. Use Tooling (B) to check the alignment of the
flywheel housing with the crankshaft. Refer
to Systems Operation, Testing and Adjusting,
Flywheel Housing - Inspect.
End By:

Illustration 70
Typical example

g01244056

a. Install the flywheel. Refer to Disassembly and

Assembly, Flywheel - Install.

44
Disassembly and Assembly Section

KENR6247

i02674882

Crankshaft Pulley - Remove

and Install
(Engines With an Automatic
Belt Tensioner)

b. Remove crankshaft pulley (4) from crankshaft

adapter (3).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Removal Procedure
Start By:
a. Remove the Alternator belt. Refer to Disassembly
and Assembly, Alternator Belt - Remove and
Install.
NOTICE
Keep all parts clean from contaminants.

1. Ensure that the crankshaft adapter, the pulley and

the thrust block are clean and free from damage.
Replace any components that are damaged. It
is possible to reclaim a crankshaft adapter with
a worn seal surface by installing a wear sleeve.
Refer to Disassembly and Assembly, Crankshaft
Wear Sleeve (Front) - Remove and Install.

Contaminants may cause rapid wear and shortened

component life.

Illustration 73

g01367385

2. If necessary, follow Steps 2.a through 2.b in order

to assemble the crankshaft pulley.
Illustration 72

g01249049

1. Use a suitable tool in order to prevent the

crankshaft from rotating. Remove bolts (1).
2. Remove thrust block (2).
3. Carefully remove the assembly of the crankshaft
pulley from the crankshaft.
4. Follow Steps 4.a through 4.b in order to
disassemble the crankshaft pulley.
a. Remove bolts (5).

a. Install crankshaft pulley (4) to crankshaft

adapter (3).
b. Install bolts (5) to the assembly of the
crankshaft pulley, and the crankshaft adapter.
The bolts should be evenly spaced.
c. Tighten the bolts to a torque of 78 Nm (58 lb ft).
3. Ensure that the front of the crankshaft is clean
and free from damage. Install the assembly of the
crankshaft pulley to the crankshaft.

KENR6247

45
Disassembly and Assembly Section

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 74

g01367392

4. Align the holes in thrust block (2) with the holes

in the crankshaft.
Note: Ensure chamfered holes (X) in thrust block (2).
Face toward the front of the engine.
5. Install thrust block (2) to the assembly of the
crankshaft pulley.
6. Install bolts (1) to thrust block (2).

Illustration 75

g01255707

1. Use a suitable tool in order to prevent the

crankshaft from rotating. Remove bolts (1).
2. Remove thrust block (2).

7. Use a suitable tool in order to prevent the

crankshaft from rotating. Tighten the bolts evenly
to a torque of 115 Nm (85 lb ft).

3. Carefully remove crankshaft pulley (3) from the

crankshaft.

8. Repeat Step 7 one more times in order to ensure

correct torque.

Installation Procedure

End By:
a. Install the alternator belt. Refer to Disassembly
and Assembly, Alternator Belt - Remove and
Install.
i02628822

Crankshaft Pulley - Remove

and Install
(Engines Without an Automatic
Belt Tensioner)
Removal Procedure
Start By:
a. Remove the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install.

Illustration 76

g01255707

1. Ensure that the crankshaft pulley and the thrust

block are clean and free from damage. Replace
any components that are damaged. It is possible
to reclaim a crankshaft pulley with a worn seal
surface by installing a wear sleeve. Refer to
Disassembly and Assembly, Crankshaft Wear
Sleeve (Front) - Remove and Install.
2. Ensure that the front of the crankshaft is clean and
free from damage. Install crankshaft pulley (3) to
the crankshaft.

46
Disassembly and Assembly Section

KENR6247

Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
- Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

g01367392

Illustration 77

3. Align the holes in thrust block (2) with the holes

in the crankshaft.
Note: Ensure chamfered holes (X) in thrust block (2).
Face toward the front of the engine.
4. Install thrust block (2) to the assembly of the
crankshaft pulley.
5. Install bolts (1) to thrust block (2).

g01266942

Illustration 78

6. Use a suitable tool in order to prevent the

crankshaft from rotating. Tighten the bolts evenly
to a torque of 115 Nm (85 lb ft).
7. Repeat Step 6 one more times in order to ensure
correct torque.

1. Install the legs of Tooling (A) behind crankshaft

front seal (1). Install a suitable spacer (2) between
Tooling (A) and crankshaft (3). Use Tooling (A) in
order to pull the crankshaft front seal out of the
front housing.
Note: Do not damage the bore for the crankshaft
front seal in the front housing.

End By:
a. Install the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install.

Installation Procedure

i02628819

Required Tools

Crankshaft Front Seal Remove and Install

Tool

Removal Procedure

Table 25

Required Tools
Tool

Part
Number

27610230

Part Description
Puller

Table 26

Qty
1

Part
Number

Part Description

Qty

21825577

Threaded Bar

21825580

Anchor Plate

21825579

Sleeve

21825578

Pressure Plate

27610217

Adapter

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

47
Disassembly and Assembly Section

1. Ensure that the bore for the crankshaft front seal in

the front housing is clean and free from damage.

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. Wear sleeves are not original equipment. A
new crankshaft front seal must be installed when a
new wear sleeve is installed.

Illustration 79

g01266453

Typical example

2. Assemble Tooling (B).

3. Align a new crankshaft front seal (1) to the front
housing.
4. Use Tooling (B) to install crankshaft front seal (1).
Ensure that the front face of the seal is installed
to a depth of 9 0.2 mm (0.354 0.008 inch) into
the front housing.

Illustration 80

5. Remove Tooling (B) from the crankshaft.

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

sleeve (1).

End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, Crankshaft Pulley - Remove and
Install.
i02628828

Crankshaft Wear Sleeve (Front)

- Remove and Install

g01269535

Sectional view of the crankshaft pulley and the wear sleeve

Note: Take care to avoid damaging to the crankshaft

pulley.
2. Insert a thin blade between wear sleeve (1) and
crankshaft pulley (2) below the scored line. The
wear sleeve will separate along the line.
3. Remove wear sleeve (1) from crankshaft pulley
(2).

Installation Procedure
Table 27

Removal Procedure
Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
- Remove and Install.
b. Remove the crankshaft front seal . Refer to
Disassembly and Assembly, Crankshaft Front
Seal - Remove and Install.

Required Tools
Tool

Part Number

21820518

Part Description
POWERPART
Liquid Gasket

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the crankshaft pulley is thoroughly
clean and dry. Remove any areas of raised
damage.

48
Disassembly and Assembly Section

Illustration 81

KENR6247

g01269521

Sectional view of the wear sleeve

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

the inner surface of wear sleeve (1) at position X.
Apply the bead of Tooling (A) 5.00 mm (0.2 inch)
from the flange end of the wear sleeve.

Illustration 83

g01258430

Sectional view of the crankshaft pulley, the wear sleeve and the
installation tool

3. Align wear sleeve (1) with crankshaft pulley (2).

Use installation tool (3) that is provided with the
wear sleeve and use a suitable press in order to
install wear sleeve (1) onto crankshaft pulley (2).
Note: Ensure that the wear sleeve is installed
squarely against the shoulder of the crankshaft pulley.
4. Remove installation tool (3) from wear sleeve (1).
5. Ensure that wear sleeve (1) has no rough edges.
End By:
a. Install a new crankshaft front seal. Refer to
Disassembly and Assembly, Crankshaft Front
Seal - Remove and Install.
Illustration 82
Typical example

g01258423

b. Install the crankshaft pulley. Refer to Disassembly

and Assembly, Crankshaft Pulley - Remove and
Install.

KENR6247

49
Disassembly and Assembly Section

i02628849

Front Cover - Remove and

Install
Removal Procedure
Start By:
a. If the engine is equipped with a fan, remove the
fan. Refer to Disassembly and Assembly, Fan
- Remove and Install.
b. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.

g01258462

Illustration 84
Typical example

1. Remove bolts (3), (4) and (5). Identify the positions

of the different bolts.
2. Remove front cover (1) from the front housing.
3. Remove joint (2) from front cover (1).

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: In order to remove the front cover, it is not
necessary to remove the crankshaft pulley or the
alternator.

Installation Procedure
Table 28

Required Tools
Tool

Part
Number

Part Name
Guide Bolt
(M8 by 80 mm)

Qty
2

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

50
Disassembly and Assembly Section

KENR6247

8. Tighten the bolts for the water pump to a torque of

22 Nm (16 lb ft).
End By:
a. If the engine is equipped with a fan, install the
fan. Refer to Disassembly and Assembly, Fan
- Remove and Install.
i02628883

Gear Group (Front) - Remove

and Install
Removal Procedure
Table 29

Required Tools
Tool

Part Number

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

A2
Illustration 85

g01343967

Typical example

1. Thoroughly clean the mating surface of the front

housing.
2. If the original front cover is installed, follow Steps
2.a and 2.b in order to install the joint.
a. Thoroughly clean the front cover.
b. Install a new joint (2) to front cover (1). Engage
locators (Y) into the holes in the front cover.
3. Install Tooling (A) into holes (X) in the front
housing.
4. Use Tooling (A) in order to position the front cover
assembly onto the front housing.
5. Install bolts (3), (4) and (5) finger tight. Ensure
that the different bolts are installed in the correct
positions.
6. Loosely install the water pump assembly and
remove Tooling (A). Refer to Disassembly and
Assembly, Water Pump - Install for the correct
procedure.
7. Tighten bolts (3), (4) and (5) to a torque of 22 Nm
(16 lb ft).

Part Name

Qty

Start By:
a. If the engine is equipped with an air compressor,
remove the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.
b. If the engine is equipped with a vacuum pump,
remove the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.
c. If the engine is equipped with an accessory drive,
remove the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.
d. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
e. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.

KENR6247

51
Disassembly and Assembly Section

Note: Do not use excessive force to install Tooling

(C). Do not use Tooling (C) to hold the crankshaft
during repairs.

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Care must be taken in order to ensure that
the fuel injection pump timing is not lost during
the removal of the front gear group. Carefully
follow the procedure in order to remove the gear
group.
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.

Illustration 87

g01322693

Typical example

3. Loosen nuts (6) on all rocker arms (7). Unscrew

adjusters (5) on all rocker arms (7) until all valves
are fully closed.
Note: Failure to ensure that ALL adjusters are fully
unscrewed can result in contact between the valves
and pistons.
4. Apply sufficient pressure to fuel injection pump
gear (3) in a counterclockwise direction in order
to remove the backlash. Lock the fuel injection
pump in this position. Refer to Disassembly and
Assembly, Fuel Pump Gear - Remove for the
correct procedure.

Illustration 86

g01247433

Typical example

2. Install Tooling (B) through hole (X) in camshaft

gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position.
Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in
the correct position. Refer to Systems Operation,
Testing and Adjusting, Finding Top Centre
Position for No.1 Piston.

Illustration 88

g01335384

Typical example

5. Mark gears (1), (2) and (3) in order to show

alignment. Refer to Illustration 88.

52
Disassembly and Assembly Section

KENR6247

Note: Identification will ensure that the gears can be

installed in the original alignment.
6. Remove fuel pump gear (3). Refer to Disassembly
and Assembly, Fuel Pump Gear - Remove for
the correct procedure.
7. Remove camshaft gear (1). Refer to Disassembly
and Assembly, Camshaft Gear - Remove and
Install.
8. Remove idler gear (2). Refer to Disassembly and
Assembly, Idler Gear - Remove and Install.

Installation Procedure
Table 30

Required Tools
Tool

Part
Number

27610212

Camshaft Timing Pin

27610286

Crankshaft Timing Pin

21825617

Dial Indicator Group

Finger Clock

Part Name

Qty

NOTICE
Keep all parts clean from contaminants.

Illustration 89

g01247433

Typical example

2. If necessary, install Tooling (C) into hole (Y) in

the front housing. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer
to Systems Operation, Testing and Adjusting,
Finding Top Centre Position for No.1 Piston.

Contaminants may cause rapid wear and shortened

component life.

Note: Do not use excessive force to install Tooling

(C). Do not use Tooling (C) to hold the crankshaft
during repairs.

Note: The fuel injection pump must remain locked

until the procedure instructs you to unlock the
fuel injection pump.

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

group are clean and free from wear of damage. If
necessary, replace any components that are worn
or damaged.

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.

Illustration 90

g01269928

Typical example

4. Install camshaft gear (1). Loosely install bolt

(6) and washer (5). Refer to Disassembly and
Assembly, Camshaft Gear - Remove and Install
for more information.

KENR6247

53
Disassembly and Assembly Section

5. Install Tooling (B) through hole (X) in camshaft

gear (1) into the front housing.

9. Install fuel injection pump gear (3). Refer to

Disassembly and Assembly, Fuel Injection Pump
Gear - Install for the correct procedure. Ensure
that timing marks on gears (2) and (3) are in
alignment. See Illustration 92. Ensure that the
mesh of the gears is correct.
10. Remove Tooling (B) and (C).
11. Use Tooling (D) in order to measure the backlash
for the gears (1), (2) and (3). Ensure that the
backlash for the gears is within specified values.
Refer to Specifications, Gear Group (Front) for
further information.
12. Lubricate each gear with clean engine oil.

Illustration 91

g01269927

Typical example

13. Adjust the engine valve lash. Refer to Systems

Operation, Testing and Adjusting, Engine Valve
Lash - Inspect/Adjust.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
b. Install the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

Illustration 92

g01335384

Alignment of timing marks

6. Install idler gear (2). Ensure that the timing marks

on gears (1) and (2) are in alignment and that the
mesh of the gears is correct. Refer to Disassembly
and Assembly, Idler Gear - Remove and Install.
Check the end play of the idler gear. Refer to
Specifications, Gear Group (Front) and refer to
Disassembly and Assembly, Idler Gear - Remove
and Install for further information.
7. Remove Tooling (B) and (C). Tighten the bolt
(6) for the camshaft gear to a torque of 95 Nm
(70 lb ft). Check the end play of the camshaft
gear. Refer to Specifications, Camshaft for more
information.
Install Tooling (B) through hole (X) in camshaft
gear (1) into the front housing and install Tooling
(C) into hole (Y) in the front housing.

c. If the engine is equipped with an air compressor,

install the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.
d. If the engine is equipped with a vacuum pump,
install the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.
e. If the engine is equipped with an accessory drive,
install the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.
i02628889

Idler Gear - Remove

Removal Procedure (Standard Idler
Gear)
Table 31

8. Ensure that the fuel injection pump is locked in

the correct position. Refer to Disassembly and
Assembly, Fuel Injection Pump - Install.

Required Tools
Tool

Part Number

Part Name

Qty

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

54
Disassembly and Assembly Section

KENR6247

Start By:
a. If the engine is equipped with an air compressor,
remove the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.

2. Ensure that Tooling (B) is installed in hole (Y) in

the front housing. Use Tooling (B) in order to lock
the crankshaft in the correct position.

b. If the engine is equipped with a vacuum pump,

remove the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.
c. If the engine is equipped with an accessory drive,
remove the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.
d. Remove the fuel injection pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear
- Remove.
e. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
g01348926

Note: Care must be taken in order to ensure that

the fuel injection pump timing is not lost during
the removal of the fuel pump gear. Carefully
follow the procedure in order to remove the fuel
pump gear.

Illustration 94

NOTICE
Keep all parts clean from contaminants.

Note: Failure to ensure that ALL adjusters are fully

unscrewed can result in contact between the valves
and pistons.

Contaminants may cause rapid wear and shortened

component life.

Typical example

3. Loosen nuts (4) on all rocker arms (5). Unscrew

adjusters (3) on all rocker arms (5) until all valves
are fully closed.

4. Mark plate (3) in order to show orientation. Refer

to Illustration 93.
Note: Identification will ensure that the plate can be
installed in the original orientation.
5. Remove bolts (1). Refer to Illustration 93.
6. Remove plate (3).

Illustration 93

g01343975

Alignment of timing marks

1. Ensure that Tooling (A) is installed into hole (X) in

the camshaft gear. Use Tooling (A) in order to lock
the camshaft in the correct position.
Note: Ensure that the gears are marked in order to
show alignment. Refer to Illustration 93.

KENR6247

55
Disassembly and Assembly Section

Note: Care must be taken in order to ensure that

the fuel injection pump timing is not lost during the
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

g01269930

Illustration 95

Note: The assembly of heavy-duty idler gear is not

serviceable. Do not disassemble the heavy-duty idler
gear.

Typical example

7. Remove the assembly of idler gear (2) and hub (7)

from the recess in the front housing.
Note: The idler gear must be tilted during removal.
8. Remove hub (7) from idler gear (2).

Removal Procedure (Heavy-Duty

Idler Gear)
Table 32

Required Tools
Part Name

Illustration 96

Tool

Part Number

Qty

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

Bolt
(M8x80mm)

Start By:
a. If the engine is equipped with an air compressor,
remove the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.
b. If the engine is equipped with a vacuum pump,
remove the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.
c. If the engine is equipped with an accessory drive,
remove the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.
d. Remove the fuel injection pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear
- Remove.
e. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

g01343977

Alignment of timing marks

1. Ensure that Tooling (A) is installed into hole (X) in

the camshaft gear. Use Tooling (A) in order to lock
the camshaft in the correct position.
Note: Ensure that the gears are marked in order to
show alignment. Refer to Illustration 96.
2. Ensure that Tooling (B) is installed in hole (Y) in
the front housing. Use Tooling (B) in order to lock
the crankshaft in the correct position.

56
Disassembly and Assembly Section

Illustration 97

KENR6247

g01348930

g01348835

Illustration 99

Typical example

Typical example

3. Loosen nuts (4) on all rocker arms (5). Unscrew

adjusters (3) on all rocker arms (5) until all valves
are fully closed.

6. If necessary, remove plate (6). Install Tooling (C)

into threaded hole (Z) in order to remove plate (6).

Note: Failure to ensure that ALL adjusters are fully

unscrewed can result in contact between the valves
and pistons.
4. Remove bolts (1) from the assembly of heavy-duty
idler gear (2). Refer to Illustration 96.

i02628887

Idler Gear - Install

Installation Procedure (Standard
Idler Gear)
Table 33

Required Tools
Tool

Part Number

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

21825617

Dial Indicator Group

Finger Clock

Illustration 98

g01269933

Typical example

Part Name

Qty

NOTICE
Keep all parts clean from contaminants.

5. Remove the assembly of idler gear (2) from the

recess in the front housing.

Contaminants may cause rapid wear and shortened

component life.

Note: The idler gear must be tilted during removal.

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 Postion for No. 1 Piston.

KENR6247

Illustration 100

57
Disassembly and Assembly Section

g01343975

Illustration 102

g01269935

Alignment of timing marks

Typical example

2. Ensure that Tooling (A) is installed into hole (X) in

camshaft gear (1).

7. Align the timing mark on idler gear (2) with the

timing mark on the camshaft gear. Refer to the
Illustration 100. Install the assembly of idler gear
(2) and hub (7) into the recess in the timing case.
Ensure that oil hole (Z) is to the top of the hub.

3. Ensure that Tooling (B) is installed in hole (Y)

in the front housing. Use Tooling (B) in order to
lock the crankshaft 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.

Ensure that the holes in the hub are aligned with the
holes in the cylinder block.
8. Clean plate (3) and inspect the plate for wear or
damage. If necessary, replace the plate.
9. Lubricate plate (3) with clean engine oil. A used
plate should be installed in the original orientation.
If a new plate is installed, ensure that the holes
in plate (3) are aligned with the holes in hub (7).
Install plate (3) to hub (7).
10. Install bolts (1). Tighten bolts (1) to a torque of
44 Nm (32 lb ft).

Illustration 101

g01269934

4. Clean idler gear (2) and inspect the idler gear for
wear or damage. Refer to Specifications, Gear
Group (Front) for more information. If necessary,
replace the idler gear.
5. Clean hub (7) and inspect the hub for wear or
damage. Refer to Specifications, Gear Group
(Front) for more information. If necessary, replace
the hub.
6. Lubricate hub (7) with clean engine oil. Slide the
hub into idler gear (2). Ensure that the timing
marks are toward the front of the idler gear.

Illustration 103

g01269936

Checking end play by using a set of feeler gauges

11. Use a set of feeler gauges in order to check the

end play for the idler gear. Refer to Specifications,
Gear Group (Front) for more information.

58
Disassembly and Assembly Section

KENR6247

12. Use Tooling (C) in order to check the backlash

between the idler gear and the camshaft gear.
Refer to Specifications, Gear Group (Front) for
more information.
13. Use Tooling (C) in order to check the backlash
between the idler gear and the crankshaft gear.
Refer to Specifications, Gear Group (Front) for
more information.
14. Lightly lubricate all of the gears with clean engine
oil.
End By:
a. Install the fuel injection pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear Install.
b. If the engine is equipped with an air compressor,
install the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.
c. If the engine is equipped with a vacuum pump,
install the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.

Illustration 104

g01343977

Alignment of timing marks

2. Ensure that Tooling (A) is installed into hole (X) in

the camshaft gear.
3. Ensure that Tooling (B) is installed in hole (Y) in
the cylinder block. Use Tooling (B) in order to
lock the crankshaft in the correct position. Refer
to Systems Operation, Testing and Adjusting,
Finding Top Centre Position for No.1 Piston.

d. If the engine is equipped with an accessory drive,

install the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.

Installation Procedure (Heavy-Duty

Idler Gear)
Table 34

Required Tools
Tool

Part Number

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

21825617

Dial Indicator Group

Finger Clock

Part Name

Qty

NOTICE
Keep all parts clean from contaminants.

Illustration 105

g01348946

Typical example

4. Install plate (6) into the recess in the front housing.

Contaminants may cause rapid wear and shortened

component life.

Note: Ensure that the identification mark TOP is

upward.

1. Ensure that number one piston is at the top

center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting,
Finding Top Center Postion for No. 1 Piston.

5. Clean the assembly of idler gear (2) and inspect

the assembly of the idler gear for wear or damage.
Refer to Specifications, Gear Group (Front)
for more information. If necessary, replace the
assembly of the idler gear.

KENR6247

59
Disassembly and Assembly Section

6. Lubricate the bearings in the assembly of idler

gear (2) with clean engine oil.

12. Lightly lubricate all of the gears with clean engine

oil.
End By:
a. Install the fuel injection pump gear. Refer to
Disassembly and Assembly, Fuel Pump Gear Install.
b. If the engine is equipped with an air compressor,
install the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and
Install.

Illustration 106

g01269933

7. Align the timing mark on idler gear (2) with the

timing mark on the camshaft gear. Refer to
Illustration 104. Install the assembly of idler gear
(2) into the recess in the timing case. Ensure that
the identification mark TOP is upward.
Note: The idler gear must be tilted during installation.
Ensure that the holes in the assembly of the idler
gear are aligned with the holes in the cylinder block.
8. Install bolts (1). Tighten bolts (1) to a torque of
44 Nm (32 lb ft).

c. If the engine is equipped with a vacuum pump,

install the vacuum pump. Refer to Disassembly
and Assembly, Vacuum Pump - Remove and
Install.
d. If the engine is equipped with an accessory drive,
install the accessory drive. Refer to Disassembly
and Assembly, Accessory Drive - Remove and
Install.
i02628886

Housing (Front) - Remove

Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
b. Remove the alternator. Refer to Disassembly and
Assembly, Alternator - Remove.
c. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
- Remove and Install.

Checking end play by using a dial indicator group

d. Remove the engine oil pan. Refer to Disassembly

and Assembly, Engine Oil Pan - Remove and
Install.

9. Use Tooling (C) in order to check the end play

of the idler gear. Refer to Specifications, Gear
Group (Front) for more information.

e. Remove the timing gears. Refer to Disassembly

and Assembly, Gear Group (Front) - Remove
and Install.

10. Use Tooling (C) in order to check the backlash

between the idler gear and the camshaft gear.
Refer to Specifications, Gear Group (Front) for
more information.

f. Remove the fuel injection pump. Refer to

Disassembly and Assembly, Fuel Injection Pump
- Remove.

Illustration 107

g01269937

11. Use Tooling (C) in order to check the backlash

between the idler gear and the crankshaft gear.
Refer to Specifications, Gear Group (Front) for
more information.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

60
Disassembly and Assembly Section

KENR6247

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Ensure that the coolant is drained into a suitable
container for storage or disposal. Refer to
Operation and Maintenance Manual, Cooling
System Coolant - Change for the correct
procedure.

Illustration 109

g01350333

3. If the engine is equipped with a heavy duty idle

gear. Remove plate (6). Refer to Disassembly and
Assembly, Idler Gear - Remove for the correct
procedure.

Illustration 108

g01337982

Typical example

2. Remove bolts (1) that secure bypass tube (2) to

front housing (3). Note the position of any brackets
that are secured by the bolts. Remove bypass
tube (2). Remove O-ring seals (4) and (5) from
bypass tube (2).

Illustration 110

g01350336

Typical example

4. Remove bolts (8), (9) and (10) from front housing

(3).
Note: The bolts are three different lengths. Note the
positions of the different bolts.
5. Remove front housing (3) from the cylinder block.
6. Remove joint (7).

KENR6247

61
Disassembly and Assembly Section

2. Check the condition of the crankshaft front seal. If

the front seal is damaged, remove the front seal
from the front housing.
3. Clean the mating surfaces of the cylinder block.

g01350337

Illustration 111
Typical example

7. Remove thrust washer (11) from the cylinder

block.
Illustration 112
i02628885

Housing (Front) - Install

g01350337

Typical example

4. Install thrust washer (11) into the recess in

the cylinder block. Refer to Disassembly
and Assembly, Camshaft - Install for more
information.

Installation Procedure
Table 35

Required Tools
Tool

Part
Number

21820117

POWERPART
Threadlock and
Nutlock

Guide Stud
(M8 by 80 mm)

27610216

Alignment Tool

Bolts
(M10 by 50 mm)

Straight Edge

21820221

POWERPART
Rubber Grease

Part Description

Qty

Illustration 113

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

g01350343

Typical example

5. Install Tooling (B) to the cylinder block. Refer to

Illustration 113.
6. Install Tooling (C) to the cylinder block.

1. Ensure that the front housing is clean and free

from damage. If necessary, replace the front
housing.
If necessary, install blanking plugs to a new front
housing. Use Tooling (A) to seal all D-plugs.

7. Align a new joint (7) with Tooling (B). Install the

joint to the cylinder block.
Note: Ensure that tabs (X) on the joint are engaged
in the holes (Y) in the cylinder block.

62
Disassembly and Assembly Section

Illustration 114

KENR6247

g01269947

Typical example

8. Install the front housing over Tooling (B) and over

Tooling (C) onto the cylinder block.
Illustration 116

g01269949

Tightening sequence for the front housing

13. Tighten bolts (8), (9) and (10) to a torque of

28 Nm (20 lb ft). Tighten the bolts in the sequence
that is shown in Illustration 116.
Note: Ensure that the housing and the cylinder block
are correctly aligned.
14. Remove Tooling (C) from the cylinder block.
15. If necessary, install a new crankshaft front seal.
Refer to Disassembly and Assembly, Crankshaft
Front Seal - Remove and Install.

Illustration 115

g01350344

(8) M8 by 20 mm
(9) M8 by 35 mm
(10) M8 by 25 mm

9. Install bolts (10) to front housing (3) finger tight.

10. Remove Tooling (B).
11. Loosely install bolts (8) and (9). Refer to
Illustration 115 for the correct position of the bolts.
12. Align the bottom face of front housing (3) to the
lower machined face of the cylinder block. Use a
Tooling (D) and a feeler gauge in order to check
the alignment between the front housing and the
cylinder block. Refer to Illustration 114. Refer to
Specifications, Front Housing and Covers for
further information.

Illustration 117

g01350333

KENR6247

63
Disassembly and Assembly Section

16. If the engine is equipped with a heavy duty idle

gear. Install plate (6). Refer to Disassembly and
Assembly, Idler Gear - Install for the correct
procedure.

i02628800

Accessory Drive - Remove and

Install
Removal Procedure
Table 36

Required Tools
Tool

Part
Number

A
Illustration 118

g01337982

Typical example

17. Install new O-ring seals (4) and (5) to bypass tube
(2). Use Tooling (E) in order to lubricate O-ring
seal (5). Install bypass tube (2) to the cylinder
head. Install bolts (1). Ensure that any brackets
that are secured by the bolts are installed in the
correct location. Tighten the bolts to a torque of
22 Nm (16 lb ft).
End By:
a. Install the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Install.
b. Install the timing gears. Refer to Disassembly and
Assembly, Gear Group (Front) - Install.

Part Description

Qty

Bearing Puller

Puller

Crossblock

Puller Leg

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.

c. Install the engine oil pan. Refer to Disassembly

and Assembly, Engine Oil Pan - Remove and
Install.
d. Install the crankshaft pulley. Refer to Disassembly
and Assembly, Crankshaft Pulley - Remove and
Install.
e. Install the alternator. Refer to Disassembly and
Assembly, Alternator - Install.
f. Install the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.

Illustration 119
Typical example

g01269954

64
Disassembly and Assembly Section

KENR6247

1. Remove allen head screw (1) from accessory

drive housing (8). Remove allen head screws (6)
from accessory drive housing (8).
2. Remove accessory drive housing (8) from the
front housing.
3. If necessary, follow Steps 3.a through 3.c in order
to disassemble the accessory drive.
a. Remove circlip (2) from accessory drive
housing (8).
b. Place accessory drive housing (8) onto a
suitable support. Press the assembly of gear
(4) and bearings (3) and (5) out of accessory
drive housing (8). Use a Tooling (A) in order to
remove bearings (3) and (5) from gear (4).
c. Remove O-ring seal (7) from accessory drive
housing (8).
Illustration 120

Installation Procedure

Typical example

1. If necessary, follow Steps 1.a through 1.e in order

to assemble the accessory drive.

Table 37

Required Tools
Tool

Part
Number

21820603

POWERPART
Retainer

21820221

POWERPART
Rubber Grease

21820117

POWERPART
Threadlock and Nutlock

Part Description

g01264852

Qty

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

a. Inspect the condition of the teeth and the

splines of gear (4) for wear or damage. Inspect
bearings (3) and (5), circlip (2), and the front
housing for wear or damage. Replace any
components that are worn or damaged.
b. Apply a small continuous bead of Tooling (B)
to inner surface (X) of bearing (5). Place the
gear shaft on a suitable support. Press on the
inner race of bearing (5) until the bearing (5) is
against the shoulder of gear (4). Remove any
excess sealant.
c. Apply a small continuous bead of Tooling (B) to
inner surface (Z) of bearing (3). Place the inner
race of bearing (3) onto a suitable support.
Press the shaft of gear (4) into bearing (3) until
the shoulder of the gear is against the bearing.
Remove any excess sealant.
d. Apply a small continuous bead of Tooling (B)
to the outer surface (Y) of bearings (3) and
(5). Place accessory drive housing (8) on a
suitable support. Press the assembly of the
gear into the accessory drive housing. Ensure
that bearing (5) is against the front face of the
recess in accessory drive housing (8). Remove
any excess sealant.
e. Install circlip (2) into the groove in accessory
drive housing (8). Ensure that circlip (2) is
correctly positioned in the groove.

KENR6247

65
Disassembly and Assembly Section

2. Lightly lubricate a new O-ring seal (7) with Tooling

(C). Install the O-ring seal into the groove in
accessory drive housing (8).

1. Loosen clamp (2) and remove hose (3) from

breather tube (1). Withdraw hose (3) from clip (4)
and remove the hose.

3. Inspect the bore in the front housing for damage.

If necessary, replace the front housing. Refer to
Disassembly and Assembly, Housing (Front)
- Remove and Disassembly and Assembly,
Housing (Front) - Install.
4. Lightly lubricate bearing (3), bearing (5), and
gear (4) with clean engine lubricating oil. Install
the assembly of the accessory drive to the front
housing. Ensure that the flange on the accessory
drive housing is flush with the front housing.
5. Apply Tooling (D) to allen head screws (1) and (6).
Install allen head screws (1) and (6) to accessory
drive housing (8).

Illustration 122

6. Tighten the allen head screws to a torque of

22 Nm (16 lb ft).

2. Remove bolt (6) and remove breather tube (1)

from valve mechanism cover (5).

7. Ensure that there is tactile backlash between the

idler gear and the accessory drive gear.

3. Remove O-ring seal (7) from breather tube(1).

g01346677

Disassembly Procedure

i02628816

Crankcase Breather - Remove

and Install
(Turbocharged Engines with
Unfiltered Breather)

Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 121
Typical example

g01343996

Illustration 123

g01347094

66
Disassembly and Assembly Section

KENR6247

1. Remove plastic cover (8) from valve mechanism

cover (5).

4. Use Tooling (A) to tighten screws (9) to a torque of

1.3 Nm (12 lb in).

2. Remove screws (9). Remove plate (10).

5. Install plastic cover (8) to valve mechanism cover

(5).

3. Remove assembly of diaphragm (11) and the cap

(12). Remove spring (13).

Assembly Procedure

NOTICE
Keep all parts clean from contaminants.

Table 38

Contaminants may cause rapid wear and shortened

component life.

Required Tools
Tool

Part
Number

27610296

Part Name
Torque Wrench

Installation Procedure

Qty
1

Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
Illustration 125

g01346677

1. Install a new O-ring seal (7) to breather tube(1).

2. Install breather tube (1) to valve mechanism cover
(5). Install bolt (6) and tighten the bolt to a torque
of 9 Nm (80 lb in).

Illustration 124

g01347094

1. Ensure that all components of the crankcase

breather are clean and free from damage. Replace
any components that are damaged.
2. Install spring (13). Install assembly of diaphragm
(11) and cap (12).
3. Position plate (10) on valve mechanism cover (5)
and install screws (9).

Illustration 126

g01343996

Typical example

3. Connect hose (3) to breather tube (1). Tighten

clamp (2). Install hose (3) into clip (4).

KENR6247

67
Disassembly and Assembly Section

i02628815

Crankcase Breather - Remove

and Install
(Turbocharged Engines with
Filtered Breather)

1. Remove canister (10). Refer to Operation and

Maintenance Manual, Crankcase Breather
(Canister) - Replace.
2. Release spring clamps (8) and remove hose (9).
3. Release spring clamps (2) in order to remove
hose (3). Remove the hose from breather tube (1)
and from filter base (5).
4. Remove bolts (6) and remove filter base (5).

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.

5. If necessary, remove bolts (7) and remove bracket

(4) from cylinder head.

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.

Illustration 128

g01368677

6. Remove bolt (12) and remove breather tube (1)

from valve mechanism cover (11).
7. Remove O-ring seal (13) from breather tube (1).

Disassembly Procedure

Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

Illustration 127
Typical example

g01368198

68
Disassembly and Assembly Section

KENR6247

g01368678

Illustration 129

1. Remove plastic cover (14) from valve mechanism

cover (11).
2. Remove screws (15). Remove plate (16).
3. Remove assembly of diaphragm (17) and the cap
(18). Remove spring (19).

Assembly Procedure
Required Tools
Part
Number

27610296

Part Name
Torque Wrench

g01368678

1. Ensure that all components of the crankcase

breather are clean and free from damage. Replace
any components that are damaged.
2. Install spring (19). Install assembly of diaphragm
(17) and cap (18).
3. Position plate (16) on valve mechanism cover (11)
and install screws (15).
4. Use Tooling (A) to tighten screws (15) to a torque
of 1.3 Nm (12 lb in).

Table 39

Tool

Illustration 130

Qty
1

Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.

5. Install plastic cover (14) to valve mechanism cover

(11).

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

69
Disassembly and Assembly Section

7. Install spring clamps (2) to hose (3). Install hose

(3) to connection (1) on the valve mechanism
cover and to filter base (4).
Note: Ensure that the spring clamps are correctly
positioned in order to secure the hose.
8. Install spring clamp (8) to hose (9). Install hose
(9) to filter base (5).
9. Install a new canister (10) to filter base (5).
Refer to Operation and Maintenance Manual,
Crankcase Breather (Canister) - Replace.
Illustration 131

g01368677

1. Install a new O-ring seal (13) to breather tube (1).

2. Install breather tube (1) to valve mechanism cover
(11). Install bolt (12) and tighten the bolt to a
torque of 9 Nm (80 lb in).

i02681626

Crankcase Breather - Remove

and Install
(Naturally Aspirated Engines)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 132

g01368198

Typical example

3. If necessary, install bracket (4). Position bracket

(4) onto cylinder head and install bolts (7). Tighten
the bolts to a torque of 22 Nm (16 lb ft).
4. Install bolts (6) to filter base (5).
5. Install the assembly of the filter base to the engine.
6. Tighten bolts (6) to a torque of 22 Nm (16 lb ft).

Illustration 133

g01368193

Typical example

1. Remove bolts (2) and remove breather tube (4)

from valve mechanism cover (1).
2. Remove O-ring seal (3) and seal (5) from breather
tube(4).

70
Disassembly and Assembly Section

KENR6247

Disassembly Procedure
Personal injury can result from parts and/or covers under spring pressure.
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.

Spring force will be released when covers are removed.

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

Be prepared to hold spring loaded covers as the

bolts are loosened.

Illustration 135
g01347463

Illustration 134
Typical example

1. Remove plastic cover (6) from valve mechanism

cover (1).

g01347463

Typical example

1. Ensure that all components of the crankcase

breather are clean and free from damage. Replace
any components that are damaged.

2. Remove screws (7). Remove plate (8).

2. Install spring (11). Install assembly of diaphragm

(10) and cap (9).

3. Remove assembly of diaphragm (9) and the cap

(10). Remove spring (11).

3. Position plate (8) on valve mechanism cover (1)

and install screws (7).

Assembly Procedure

4. Use Tooling (A) to tighten screws (7) to a torque of

1.3 Nm (12 lb in).

Table 40

5. Install plastic cover (6) to valve mechanism cover

(1).

Required Tools
Tool

Part
Number

27610296

Part Name
Torque Wrench

Qty
1

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

71
Disassembly and Assembly Section

1. If the engine is equipped with a cover for the fuel

injectors, remove the cover for the fuel injectors.
Refer to Disassembly and Assembly, Fuel
Injector Cover - Remove and Install.
2. If the engine is equipped with a heat shield,
remove the heat shield.

Illustration 136

g01368193

Typical example

1. Install new O-ring seals (3) and (5) to breather

tube(4).
2. Install breather tube (4) to valve mechanism cover
(1). Install bolts (2) and tighten the bolt to a torque
of 9 Nm (80 lb in).
i02628915

Valve Mechanism Cover Remove and Install

Removal Procedure
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Illustration 137

g01368184

Typical example

3. Remove breather tube (2) from valve mechanism

cover (1). Refer to Disassembly and Assembly,
Crankcase Breather - Remove and Install.
4. Loosen captive bolts (3). Remove valve
mechanism cover (1).
5. Remove captive bolts (3) and remove joint (4) (not
shown) from valve mechanism cover (1).

72
Disassembly and Assembly Section

KENR6247

Installation Procedure

6. Tighten the captive bolts for the valve mechanism

cover in the sequence that is shown in Illustration
139. Tighten the captive bolts to a torque of 9 Nm
(80 lb in).
7. Install breather tube (3) to valve mechanism
cover (1). Refer to Disassembly and Assembly,
Crankcase Breather - Remove and Install.
8. If the engine is equipped with a heat shield, install
the heat shield.
9. If the engine is equipped with a cover for the fuel
injectors, install the cover for the fuel injectors.
Refer to Disassembly and Assembly, Fuel
Injector Cover - Remove and Install.
i02628906

Rocker Shaft and Pushrod Remove

Illustration 138

g01368184

Typical example

1. Thoroughly clean valve mechanism cover (1).

Ensure that the groove for the joint in the valve
mechanism cover is clean and dry. Ensure that
the mating surface on the cylinder head is clean
and dry.
2. Check the condition of captive bolts (3). If
necessary, replace the captive bolts.
3. Install a new joint (4) to valve mechanism cover
(1). Ensure that the joint is seated correctly in the
groove in the valve mechanism cover.
4. Install captive bolts (3) to valve mechanism cover
(1).
5. Position valve mechanism cover (1) onto the
cylinder head.

Removal Procedure
Table 41

Required Tools
Tool

Part
Number

27610227

Part Description

Qty

E10 Torx Socket

Rocker Assembly Tool

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.

Illustration 139
Sequence for tightening the isolating bolts

g01344009

KENR6247

Illustration 140

73
Disassembly and Assembly Section

g01323013

g01359104

Illustration 141

Typical example

Typical example

1. Use Tooling (A) to progressively loosen torx

screws (1). Begin at the ends of the rocker shaft
assembly and work toward the center.

5. Place an identification mark on pushrods (3) in

order to show the location. Remove the pushrods
from the cylinder head.

Note: To avoid distortion of the rocker shaft assembly,

each torx screw should be loosened by a quarter of a
turn at one time. Repeat the procedure until all torx
screws are loosened.

Note: Identification will ensure that the pushrods

can be reinstalled in the original positions. Do not
interchange the positions of used pushrods.

2. Remove torx screws (1) from rocker shaft

assembly (2).

i02628903

Rocker Shaft - Disassemble

3. If the rocker shaft will not be disassembled, install

Tooling (B) between each pair of rocker arms.
4. Remove rocker shaft assembly (2) from the
cylinder head.

Disassembly Procedure
Table 42

Required Tools
Tool

Part
Number

Part Description
Circlip Pliers

Qty
1

Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

74
Disassembly and Assembly Section

KENR6247

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

6. If necessary, remove nuts (8) and adjusters

(9) from the rocker arms. Make a temporary
identification mark on each adjuster in order to
show the location.
Note: The components must be reinstalled in the
original location. Do not interchange components.
i02628901

Rocker Shaft - Assemble

1. Make an identification mark on each rocker arm

assembly in order to show the location.
Note: The components must be reinstalled in the
original location. Do not interchange components.

Assembly Procedure
Table 43

Required Tools
Tool

Part
Number

Part Description
Circlip Pliers

Qty
1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that all components are clean and free
from wear or damage. Refer to Specifications,
Rocker Shaft for more information. If necessary,
replace any components that are worn or
damaged.

Illustration 142

g01350909

Typical example

2. Use Tooling (A) to remove circlip (1) and remove

washer (2) from both ends of the rocker shaft
assembly.
Note: The rocker shaft (7) is not symmetrical as there
is a machined flat (6) toward one end of the shaft.
3. Remove rocker arm assembly (3) for the inlet
valve from rocker shaft (7). Remove rocker arm
assembly (4) for the exhaust valve from rocker
shaft (7).
4. Remove spring (5) from rocker shaft (7).
5. Repeat Step3 and Step4 in order to completely
disassemble the rocker shaft assembly.
Illustration 143
Typical example

g01350909

KENR6247

75
Disassembly and Assembly Section

2. If necessary, install adjusters (9) and nuts (8) to

rocker arm assemblies (3) and (4). If the original
adjusters are reused, ensure that the adjusters
are installed in the original positions.
3. Use Tooling (A) to install circlip (1) and washer (2)
to the front end of rocker shaft (7).
4. Lubricate the bores of rocker arm assemblies (3)
and (4) and rocker shaft (7) with clean engine oil.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Clean the pushrods. Inspect the pushrods for
wear or damage. Replace any pushrods that are
worn or damaged.

5. Install rocker arm assembly (3) for number 1

cylinder inlet valves to the rocker shaft. Install
rocker arm assembly (4) for number 1 cylinder
exhaust valves to rocker shaft (7).

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.
6. Install spring (5) to rocker shaft (7).
7. Repeat Steps 5 to 6 in order to assemble the
remaining components to rocker shaft (7).
8. Install washer (2) to rocker shaft (7). Use Tooling
(A) to install circlip (1).

Illustration 144

g01359104

Typical example

End By:
a. Install the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Install.
i02628904

Rocker Shaft and Pushrod Install

4. If the rocker shaft assembly was disassembled,

install Tooling (B) between each pair of rocker
arms.

Table 44

Required Tools
Part
Number

27610227

Part Description

Note: Ensure that the pushrods are installed in the

original location and that the ball end of each pushrod
is correctly seated in the valve lifters.
3. Ensure that the rocker shaft assembly is clean
and free from wear or damage.

Installation Procedure

Tool

2. Apply clean engine lubricating oil to both ends of

pushrods (3). Install the pushrods to the engine
with the cup upward.

Qty

E10 Torx Socket

Rocker Assembly Tool

76
Disassembly and Assembly Section

KENR6247

8. Use Tooling (A) to progressively tighten torx

screws (1). Begin at the center of the rocker shaft
assembly and work toward the ends.
Note: To avoid distortion of the rocker shaft assembly,
each torx screw should be tightened by a quarter of a
turn at one time. Repeat the procedure until all torx
screws are tightened.
Tighten torx screws (1) to a torque of 35 Nm
(26 lb ft).
9. Check the valve lash. Refer to Systems Operation,
Testing and Adjusting, Engine Valve Lash Inspect/Adjust. If necessary, adjust the valve
lash. Refer to Systems Operation, Testing and
Adjusting, Engine Valve Lash - Inspect/Adjust for
the correct procedure.
End By:
Illustration 145

g01323445

Typical example

a. Install the valve mechanism cover. Refer to

Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

5. Ensure that the machined flat (X) is facing upward,

and facing the front end of the engine.
6. Position rocker shaft assembly (2) onto the
cylinder head.
Note: Ensure that adjustment screws are properly
seated in the ends of pushrods (3).
7. Install torx screws (1) to the rocker shaft assembly
finger tight.

i02628830

Cylinder Head - Remove

Removal Procedure
Start By:
a. Remove the exhaust manifold. Refer to
Disassembly and Assembly, Exhaust Manifold
- Remove and Install.
b. Remove the injectors. Refer to Disassembly and
Assembly, Injector - Remove.
c. Remove the rocker shaft assembly and the
pushrods. Refer to this Disassembly and
Assembly Manual, Rocker Shaft and Pushrod Remove.
d. Remove the glow plugs. Refer to Disassembly
and Assembly, Glow Plugs - Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 146
Typical example

g01323447

KENR6247

77
Disassembly and Assembly Section

6. Disconnect the harness assembly from sensor (1).

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

7. Remove the bolts (2). Remove the bypass tube

(3) from the cylinder head. Remove O-ring seals
(4) and (5).

Dispose of all fluids according to local regulations and

mandates.
Note: Put identification marks on all hoses, on all
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
1. If the alternator bracket is mounted on the cylinder
head, remove the alternator. Refer to Disassembly
and Assembly, Alternator - Remove.
2. If the fuel priming pump and the fuel filter base are
mounted on the cylinder head, remove the fuel
priming pump and the fuel filter base. Refer to
Disassembly and Assembly, Fuel Priming Pump
and Fuel Filter Base - Remove and Install.

Illustration 148

g01323622

Typical example

3. 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 for the correct
draining procedure.
4. Disconnect the upper radiator hose from the water
temperature regulator housing.
5. If necessary, remove the air hose from the inlet
connection.

Illustration 149

g01352264

Sequence for tightening the bolts for the cylinder head

8. Gradually loosen bolts (6) in the reverse numerical

order to the sequence that is shown in Illustration
149.
Note: Follow the correct sequence in order to help
prevent distortion of the cylinder head.
9. Remove bolts (6) from cylinder head (7).
Illustration 147

g01344073

78
Disassembly and Assembly Section

KENR6247

Note: The bolts are two different lengths. Note the

positions of the different bolts.

g01323639

Illustration 151
Typical example

12. Remove cylinder head gasket (10).

13. Note the position of dowels (9) in the cylinder
block. Do not remove the dowels unless the
dowels are damaged.
Illustration 150

g01323631

Typical example

14. If necessary, remove the sensor from cylinder

head.

10. Attach a suitable lifting device (8) to cylinder head

(7). Support the weight of the cylinder head. The
weight of the cylinder head is approximately 56 kg
(124 lb).

15. If necessary, remove the water temperature

regulator from the cylinder head. Refer to
Disassembly and Assembly, Water Temperature
Regulator - Remove and Install.

Note: It is advisable to use a spreader bar during the

lifting operation in order to distribute the weight of
the cylinder head .

i02628829

Cylinder Head - Install

11. Use lifting device (8) to carefully lift cylinder head

(7) off the cylinder block.
Note: Do not use a lever to separate the cylinder
head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head
during the removal procedure.
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.

Installation Procedure
Table 45

Required Tools
Tool

Part
Number

Guide Bolt
(M16 by 115mm)

Straight Edge

21825607

Degree Wheel

21820221

POWERPART
Rubber Grease

Part Description

Qty

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

79
Disassembly and Assembly Section

1. Thoroughly clean the mating surfaces of the

cylinder head and the cylinder block. Do not
damage the mating surfaces of the cylinder head
or the cylinder block. Ensure that no debris enters
the cylinder bores, the coolant passages, or the
lubricant passages.
2. Inspect the mating surface of the cylinder head for
distortion. Refer to Specifications, Cylinder Head
for more information.

Illustration 153

g01323631

Typical example

6. Use a suitable lifting device (8) to lift the

cylinder head. The weight of the cylinder head is
approximately 56 kg (124 lb).

Illustration 152

g01324063

Typical example

3. Inspect dowels (9) for damage. If necessary,

replace the dowels in the cylinder block.
4. Install Tooling (A) to the cylinder block. Refer to
Illustration 152.

Note: It is advisable to use a spreader bar during

the lifting operation in order to distribute the weight
of the cylinder head.
7. Use Tooling (A) to align cylinder head (7) with
the cylinder block. Install the cylinder head to the
cylinder block.
Note: Ensure that the cylinder head is correctly
positioned onto dowels (9).

5. Align cylinder head gasket (10) with Tooling (A)

and with dowels (9). Install the cylinder head
gasket onto the cylinder block.

Illustration 154

g01324064

8. Clean bolts (6). Follow Steps 8.a and 8.b for the
procedure to inspect the bolts.
a. Check the length of the bolts.

80
Disassembly and Assembly Section

KENR6247

b. Use Tooling (B) in order to check the threads of

the bolts. Refer to Illustration 154. Replace any
bolts that show visual reduction in the diameter
of the thread over length (Y).
9. Lubricate the threads and the shoulder of bolts
(6) with clean engine oil.
10. Remove Tooling (A).

Illustration 157

g01352369

(A) Short bolts

(B) Long bolts

14. Use Tooling (C) to turn bolts (6) through an

additional angle in the sequence that is shown in
Illustration 156.
Turn the long bolts through 270 degrees.
Turn the short bolts through 225 degrees.

Illustration 155

g01323622

11. Install bolts (6) to cylinder head (7).

Note: There are two different lengths of bolts (6) for
cylinder head (7). Install longer bolts in position (X)
in the cylinder head.

Illustration 158

Illustration 156

g01352300

Sequence for tightening the bolts for cylinder head

12. Tighten bolts (6) to a torque of 50 Nm (37 lb ft) in

the sequence that is shown in Illustration 156.
13. Tighten bolts (6) to a torque of 100 Nm (74 lb ft)
in the sequence that is shown in Illustration 156.

g01344073

15. Install new O-ring seals (4) and (5) to bypass tube
(3). Use Tooling (D) in order to lubricate the O-ring
seal (5). Install the bypass tube to the cylinder
head. Install bolts (2). Ensure that any brackets
that are secured by the bolts are installed in the
correct position. Tighten the bolts to a torque of
22 Nm (16 lb ft).
16. Connect the harness assembly to sensor (1).

KENR6247

81
Disassembly and Assembly Section

17. If the alternator bracket is mounted on the cylinder

head, Install the alternator. Refer to Disassembly
and Assembly, Alternator - Remove.
18. Install the injectors. Refer to Disassembly and
Assembly, Injector - Install.
19. Install the glow plugs. Refer to Disassembly and
Assembly, Glow Plugs - Remove and Install.
20. If the fuel priming pump and the fuel filter base
are mounted on the cylinder head, install the fuel
priming pump and the fuel filter base. Refer to
Disassembly and Assembly, Fuel Priming Pump
and Fuel Filter Base - Remove and Install.
21. Install the exhaust manifold. Refer to Disassembly
and Assembly, Exhaust Manifold - Remove and
Install.
22. If necessary, install the air hose to the inlet
connection.

Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.
b. Remove the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. If the crankshaft is installed, use Tooling (A) to
rotate the crankshaft in order to gain access to
lifters (1).

23. If necessary, install the water temperature

regulator housing to the cylinder head. Refer to
Disassembly and Assembly, Water Temperature
Regulator Housing - Remove and Install.
24. Connect the upper radiator hose to the water
temperature regulator housing .
25. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, Cooling
System Coolant - Change for the correct filling
procedure.
26. If necessary, fill the engine oil pan to the correct
level. Refer to Operation and Maintenance
Manual, Engine Oil Level - Check.
i02628895

Lifter Group - Remove and

Install

g01340518

Illustration 159
Typical example

2. Use Tooling (B) in order to remove lifters (1).

Note: Make a temporary identification mark on each
lifter in order to identify the correct location.
3. Repeat Steps 1 and 2 in order to remove the
remaining lifters.

Removal Procedure

Installation Procedure

Table 46

Table 47

Required Tools

Required Tools

Tool

Part
Number

Part Description

Qty

Tool

Part
Number

Part Description

Qty

21825576

Crankshaft Turning Tool

21825576

Crankshaft Turning Tool

Telescopic Magnet

Telescopic Magnet

82
Disassembly and Assembly Section

KENR6247

End By:
NOTICE
Keep all parts clean from contaminants.

a. Install the camshaft. Refer to Disassembly and

Assembly, Camshaft - Remove and Install.

Contaminants may cause rapid wear and shortened

component life.
NOTICE
It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
1. Clean the lifters. Follow Steps 1.a through 1.c in
order to inspect the lifters. Replace lifters that are
worn or damaged.
a. Inspect the seat of the pushrod in the lifter for
visual wear or damage.
b. Inspect the shank of the lifter for wear or
damage. Refer to Specifications, Lifter Group
for more information.
c. Inspect the face of the lifter that runs on the
camshaft for visual wear or damage.
2. If the crankshaft is installed, use Tooling (A) to
rotate the crankshaft. Rotate the crankshaft to
access to the cylinder block in order to install
lifters (1).
3. Lubricate lifters (1) with clean engine oil.

b. If the engine is equipped with a balancer, install

the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.
i02628809

Camshaft - Remove and Install

Removal Procedure
Start By:
a. Remove the rockershaft and pushrods. Refer to
Disassembly and Assembly, Rocker shaft and
Pushrod - Remove.
b. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. The engine should be mounted on a suitable
stand and placed in the inverted position.

Illustration 160

g01340518

Typical example

4. Use Tooling (B) to install lifters (1) to the cylinder

block. Ensure that used lifters are installed in the
correct location.
Note: The lifters should be free to rotate.
5. Repeat Steps 1 and 4 in order to install the
remaining lifters.

Illustration 161

g01266056

Typical example

2. Remove thrust washer (1) from the cylinder block.

Do not remove dowel (2) from the cylinder block
unless the dowel is damaged.

KENR6247

83
Disassembly and Assembly Section

Note: The thrust washer can have one or two slots

(X).

Illustration 163
Illustration 162

g01266057

NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
3. Carefully remove camshaft (3) from the cylinder
block.
4. Do not remove key (4) from camshaft (3) unless
the key is damaged.

g01266057

4. If necessary, install a new key (4) to camshaft (3).

5. Lubricate the bearing surfaces of camshaft (3)
and lubricate the lobes of the camshaft with clean
engine oil.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
6. Carefully install camshaft (3) into the cylinder
block.

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Clean the camshaft and the thrust washer. Inspect
the camshaft and the thrust washer for wear and
for damage. Refer to Specifications, Camshaft
for more information. Replace any components
that are worn or damaged.
2. Clean the camshaft bearing in the cylinder
block. Inspect the camshaft bearing for wear
and for damage. Refer to Specifications,
Camshaft Bearings for more information. If
necessary, replace the camshaft bearing. Refer to
Disassembly and Assembly, Camshaft Bearing
- Remove and Install.
NOTICE
It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
3. Inspect the lifters for wear and for damage.
Refer to Specifications, Lifter Group for more
information. Replace any worn lifters or any
damaged lifters. Refer to Disassembly and
Assembly, Lifter Group - Remove and install.

Illustration 164

g01266056

Typical example

7. Lubricate the thrust washer with clean engine oil.

Align slot (X) in thrust washer (1) with dowel (2) in
the cylinder block. Install thrust washer (1) into the
recess in the cylinder block.
Note: The thrust washer can have one or two slots.
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Install.
b. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, Rocker shaft and
Pushrod - Install.

84
Disassembly and Assembly Section

KENR6247

i02628811

Camshaft Gear - Remove and

Install
Removal Procedure
Table 48

Required Tools
Tool

Part Number

Part Name

Qty

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

A2

Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
b. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.

Illustration 165

g01255712

Typical example

2. Install Tooling (B) through hole (X) in camshaft

gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position.
3. Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in
the correct position.
Note: Do not use excessive force to install Tooling
(C). Do not use Tooling (C) to hold the crankshaft
during repairs.

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Illustration 166

g01350327

Typical example

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.

4. Loosen nuts (6) on ALL rocker arms (7). Unscrew

adjusters (5) on all rocker arms (7) until all valves
are fully closed.
Note: Failure to ensure that all adjusters are fully
unscrewed can result in contact between the valves
and pistons.

KENR6247

85
Disassembly and Assembly Section

Installation Procedure
Table 49

Required Tools
Tool

Part
Number

27610212

Camshaft Timing Pin

27610211

Crankshaft Timing Pin

21825617

Dial Indicator Group

Finger Clock

Illustration 167

g01344527

Alignment of timing marks

5. Mark gears (1) and (4) in order to show alignment.

Refer to Illustration 167.
Note: Identification will ensure that the gears can be
installed in the original alignment.

Illustration 168

Part Name

Qty

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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.

g01340554

Typical example
Illustration 169

6. Remove Tooling (B) and Tooling (C). Remove bolt

(3) and washer (2) from camshaft gear (1).
7. Remove camshaft gear (1) from the camshaft.
Note: If the camshaft gear is a tight fit on the nose
of the camshaft, use a prybar in order to remove the
camshaft gear.
8. If necessary, remove the key from the nose of
the camshaft.

g01255712

Typical example

2. Install Tooling (C) into hole (Y) in the cylinder block.

Use Tooling (C) in order to lock the crankshaft in
the correct position. Refer to Systems Operation,
Testing and Adjusting, Finding Top Centre
Position for No.1 Piston.
3. Ensure that the camshaft gear and the key are
clean and free from wear or damage.
4. If necessary, install the key into the nose of the
camshaft.
Note: Ensure that the key is squarely seated.

86
Disassembly and Assembly Section

KENR6247

12. Adjust the valve lash. Refer to Systems Operation,

Testing and Adjusting, Engine Valve Lash Inspect/Adjust.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
b. Install the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.

Illustration 170

g01344527

Alignment of timing marks

5. Align the keyway in camshaft gear (1) with the key

in the camshaft. Install the camshaft gear onto the
camshaft. Ensure that the timing marks on gears
(1) and (8) are in alignment and that the mesh of
the gears is correct. Refer to Illustration 170.

i02628810

Camshaft Bearings - Remove

and Install
Removal Procedure
Table 50

Required Tools
Tool

Part
Number

27610275

Part Description
Bearing Puller Group

Qty
1

Start By:

Illustration 171

g01340554

a. If the engine is equipped with a balancer, remove

the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.

Typical example

6. Install Tooling (B) through hole (X) in the camshaft

gear into the front housing. Install washer (2) and
bolt (3) to camshaft gear (1).
7. Remove Tooling (B) and (C).
8. Tighten bolt (3) to a torque of 95 Nm (70 lb ft).
9. Use Tooling (D) to check the backlash for gears (1)
and (8). Ensure that the backlash for the gears is
within specified values. Refer to the Specifications,
Gear Group (Front) for further information.
10. Use Tooling (D) to check the end play for
camshaft gear (1). Ensure that the end play is
within specified values. Refer to the Specifications,
Camshaft for further information.
11. Lubricate the teeth of the gears with clean engine
oil.

b. Remove the camshaft. Refer to Disassembly and

Assembly, Camshaft - Remove and Install.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

KENR6247

87
Disassembly and Assembly Section

2. Lubricate the bearing housing in the cylinder block

with clean engine oil.
3. Accurately align the two oil holes (X) in camshaft
bearing (1) with the two oil holes in the cylinder
block.
Note: The groove (Y) in the camshaft bearing must
be to the top of the cylinder block.

g01270437

Illustration 172

4. Use Tooling (A) in order to install camshaft bearing

(1) into the cylinder block. Install the camshaft
bearing so that the front edge of the bearing is
flush with the face of the recess in the cylinder
block.
Note: Ensure that all oil holes are correctly aligned.
If the oils are not correctly aligned, the camshaft
bearing should be removed.

1. Inspect camshaft bearing (1). Refer to

Specifications, Camshaft Bearings for more
information.
2. If camshaft bearing (1) is worn or damaged use
Tooling (A) in order to remove the camshaft
bearing from the cylinder block.
Note: Remove the camshaft bearing from the front of
the cylinder block.

Installation Procedure
Table 51

End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove and Install.
b. If the engine is equipped with a balancer, install
the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.

Required Tools
Tool

Part
Number

27610271

i02628836

Part Description
Bearing Puller Group

Qty
1

NOTICE
Keep all parts clean from contaminants.

Engine Oil Pan - Remove and

Install
(Aluminum and Pressed Steel
Oil Pans)

Contaminants may cause rapid wear and shortened

component life.

Removal Procedure
1. Clean the bearing housing in the cylinder block.
Ensure that the oil holes in the bearing housing
are free from debris.

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Illustration 173

g01266512

Dispose of all fluids according to local regulations and

mandates.

88
Disassembly and Assembly Section

KENR6247

2. Remove O-ring seal (11) from drain plug (5).

3. Disconnect breather hose (1) from clip (6).
Position the breather hose away from the engine
oil pan.
4. If necessary, remove the assembly of dipstick
tube. Loosen nut (3) and remove tube assembly
(2). Remove seal (4) from the tube assembly.
Note: Identify the position and orientation of the tube
assembly.
5. Support the assembly of the engine oil pan.
Mark the position of clip (6). Loosen the bolt that
secures the clip and remove the clip.
6. Remove bolts (9) and (10).
7. Remove engine oil pan (8) and remove joint (7)
from the cylinder block.
Illustration 174

g01344541

Installation Procedure

Typical example

1. Place a suitable container below the engine

oil pan. Remove drain plug (5) and drain the
engine lubricating oil. Refer to Operation and
Maintenance Manual, Engine Oil and Filter Change for the correct procedure.

Table 52

Required Tools
Tool

Part
Number

B
C

Part Description

Qty

Guide Stud
(M8 by 100 mm)

21826038

POWERPART
Silicon Rubber Sealant

21820117

POWERPART
Threadlock and Nutlock

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the mating surface of the cylinder
block is clean and free from damage.

Illustration 175
Typical example

g01251767

KENR6247

89
Disassembly and Assembly Section

Illustration 178

g01251766

Typical example

4. Apply a bead of Tooling (B) to positions (Y) on the

cylinder block.
Illustration 176

g01251768

Typical example

Note: If the bridge piece for the cylinder block has

just been installed, the engine oil pan must be
installed before Tooling (B) has cured.

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

block.
3. Ensure that the engine oil pan is clean and free
from damage.

Illustration 177

g01251763

Typical example

Illustration 179

g01251767

Typical example

5. Position a new joint (7) onto engine oil pan (8).

90
Disassembly and Assembly Section

KENR6247

i02628835

Engine Oil Pan - Remove and

Install
(Cast Iron Oil Pan)
Removal Procedure
Note: In order to remove a cast iron oil pan, the
engine must be removed from the machine. Ensure
that the engine lubricating oil is drained. Refer to
Operation and Maintenance Manual, Engine Oil and
Filter - Change for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Illustration 180

g01344541

Typical example

6. Align the assembly of the engine oil pan with

Tooling (A). Install the assembly of the engine oil
pan to the cylinder block.
7. Install bolts (9) finger tight. Install clip (6) in the
correct position.
8. Remove Tooling (A).
9. Apply Tooling (C) to bolts (10). Install bolts (10)
and the remaining bolts (9).
10. Tighten bolts (9) and (10) to a torque of 22 Nm
(16 lb ft).
11. Install a new O-ring seal (11) to drain plug (5).
Install the drain plug to engine oil pan (8). Tighten
the oil drain plug to a torque of 34 Nm (25 lb ft).
12. If necessary, follow Steps 12.a through 12.c in
order to install the assembly of the dipstick tube.
a. Install a new seal (4) to tube assembly (2).
b. Apply Tooling (C) to nut (3). Install the tube
assembly to the engine oil pan.
Note: Ensure that the orientation of the tube
assembly is correct.
c. Tighten nut (3) to a torque of 18 Nm (13 lb ft).
Install the dipstick.
13. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, Engine Oil
and Filter - Change for the procedure.

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. The engine should be mounted in a suitable stand
and placed in the inverted position.

KENR6247

Illustration 181

91
Disassembly and Assembly Section

g01344541

Typical example

2. Disconnect breather hose (1) from clip (6).

Position the breather hose away from the engine
oil pan.
Note: Identify the position and orientation of the tube
assembly before removal.
3. Remove the assembly of the dipstick tube. Loosen
nut (3) and remove tube assembly (2). Remove
seal (4) from the tube assembly.

Illustration 182

g01251978

Typical example

4. Mark the position of clip (6). Refer to Illustration

181. Loosen the bolt that secures the clip and
remove the clip.
5. Remove nuts (10) and bolts (9).
Note: The bolts are different lengths. Note the
position of the different bolts.
6. Attach a suitable lifting device to engine oil pan
(8). Support the weight of the engine oil pan. The
engine oil pan weighs approximately 41 kg (90 lb).
7. Use the lifting device to remove engine oil pan (8)
from the cylinder block.
8. Remove joint (7) from the cylinder block.
9. If necessary, remove drain plug (5). Remove
O-ring seal (11) from oil drain plug (5).

92
Disassembly and Assembly Section

KENR6247

Installation Procedure
Table 53

Required Tools
Tool

Part
Number

21826038

POWERPART
Silicon Rubber Sealant

21820117

POWERPART
Threadlock and Nutlock

Straight Edge

Part Description

Qty

Note: In order to install a cast iron oil pan, the engine

must be removed from the machine.

Illustration 184

NOTICE
Keep all parts clean from contaminants.

3. Apply a bead of Tooling (A) to positions (Y) on the

cylinder block.

Contaminants may cause rapid wear and shortened

component life.

Note: If the bridge piece for the cylinder block has

just been installed, the engine oil pan must be
installed before Tooling (A) has cured.

g01251766

Typical example

1. Ensure that the mating surface of the cylinder

block is clean and free from damage. Inspect
the studs in the cylinder block for damage. If
necessary, replace the studs.
2. Ensure that the engine oil pan is clean and free
from damage.

Illustration 183

g01251763

Typical example

Illustration 185

g01251978

Typical example

4. Align a new joint (7) with the studs in the cylinder

block. Install the joint to the cylinder block.
5. Attach a suitable lifting device to engine oil pan
(8). The engine oil pan weighs approximately
41 kg (90 lb).

KENR6247

93
Disassembly and Assembly Section

6. Use the lifting device to align engine oil pan (8)

with the studs in the cylinder block. Install the
engine oil pan to the cylinder block. Remove the
lifting device from the engine oil pan.

11. Follow Steps 11.a through 11.c in order to install

the assembly of the dipstick tube.

7. Install bolts (9) and nuts (10) finger tight. Install

the clip (6).

b. Apply Tooling (B) to nut (3). Install the tube

assembly to the engine oil pan.

a. Install a new seal (4) to tube assembly (2).

Note: Ensure that the orientation of the tube

assembly is correct.
c. Tighten the nut to a torque of 18 Nm (13 lb ft).
Install the dipstick .
12. Install breather hose (1) to clip (6).
Note: After the engine has been installed, ensure that
the engine oil pan is filled with lubricating oil to the
correct level. Refer to Operation and Maintenance
Manual, Engine Oil and Filter - Change for the
correct procedure.
Illustration 186

g01251982
i02628808

Typical example

8. Align the rear face of engine oil pan (8) to the rear
face of cylinder block (12). Use Tooling (C) and
a feeler gauge in order to check the alignment
between the engine oil pan and the cylinder block.
9. Tighten bolts (9) and nuts (10) to a torque of
22 Nm (16 lb ft).

Balancer - Remove
Removal Procedure
Table 54

Required Tools

10. If necessary, install a new O-ring seal (11) to drain

plug (5). Install drain plug (5) to engine oil pan
(8). Tighten the drain plug to a torque of 34 Nm
(25 lb ft).

Tool

Part
Number

21825576

Crankshaft Turning Tool

27610211

Crankshaft Timing Pin

27610225

Timing Pin (Balancer)

Puller (Two Leg)

Part Name

Qty

Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
b. Remove the front cover. Refer to Disassembly
and Assembly, Front Cover - Remove and Install.
Note: In order to remove the balancer, the engine
must be removed from the machine. The engine
should be mounted in a suitable stand and placed
in the inverted position.

Illustration 187
Typical example

g01344541

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

94
Disassembly and Assembly Section

KENR6247

3. Remove bolts (3) and suction pipe (2).

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

4. Remove the joint from the suction pipe.

Dispose of all fluids according to local regulations and

mandates.
1. Use Tooling (A) in order to rotate the crankshaft
so that number one piston is at the top center
position.

Illustration 190

g01252310

Typical example

5. Install Tooling (C) into balancer (1). Ensure that

Tooling (C) is engaged into the hole in drive shaft
(5).
6. Attach a suitable lifting device to balancer (1).
Support the weight of the balancer. The balancer
weighs approximately 23 kg (51 lb).

Illustration 188

g01259627

7. Remove bolts (4). Use the lifting device to remove

the balancer.

Typical example

2. Install Tooling (B) through hole (X) in the front

housing. Use Tooling (B) in order to lock the
crankshaft in the correct position.

Illustration 191

g01259636

8. Do not remove dowels (6) and (7) unless the

dowels are damaged.
Note: The balancer unit is not a serviceable item.
The engine oil pump and the engine oil relief valve
are the only serviceable parts of the balancer.

Disassembly Procedure
Illustration 189
Typical example

g01259635

1. Remove the engine oil relief valve. Refer to

Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install.

KENR6247

95
Disassembly and Assembly Section

i02628805

Balancer - Install
Assembly Procedure
Table 55

Required Tools
Tool

Part Number

21820117

Part Description
POWERPART
Threadlock and Nutlock

Qty
1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that all components of the engine oil pump
are clean and free from wear or damage.

Illustration 192

g01344542

2. Remove bolt (8) and hub (9). Remove idler gear

(10) and thrust washer (11).

Illustration 193

g01259631

3. Remove nut (12). Use Tooling (D) in order to

remove gear (13) from the shaft of the oil pump.
Note: Do not use a timing pin to lock the balancer in
order to loosen nut (12).
4. Remove bolts (14) and remove front cover (15).
5. Remove outer rotor (17) and remove inner rotor
(16).
Note: Mark the direction of rotation of the rotors.

Illustration 194
Typical example

g01344542

96
Disassembly and Assembly Section

KENR6247

2. Install inner rotor (16) and outer rotor (17). Used

rotors should be installed in the original direction
of rotation. Check the clearance between the outer
rotor and the body of the oil pump. Check the
clearance between the inner rotor and the outer
rotor. Check the end play of the rotor assembly.
Refer to Specifications, Engine Oil Pump for
more information.
3. Lubricate the assembly of the oil pump with clean
engine oil. Install front cover (15). Install bolts (14).
Tighten the bolts to a torque of 26 Nm (19 lb ft).
4. Ensure that the shaft of the oil pump is clean
and dry. Position gear (13) onto the shaft. Install
nut (12). Tighten the nut to a torque of 95 Nm
(70 lb ft).
Note: Do not use a timing pin to lock the balancer in
order to tighten nut (12).
5. Lubricate hub (9), thrust washer (11) and the bush
of idler gear (10) with clean engine oil. Install hub
(9) and thrust washer (11) to idler gear (10).

Illustration 195

g01259627

1. Ensure that No. 1 piston is at the top center

position and that Tooling (B) is installed to position
(X) in the front housing.
2. Clean the mating surfaces of the cylinder block.

Note: Ensure the correct orientation of the idler gear.

6. Install the assembly of the idler gear to balancer
(1).
7. Ensure that the threads of bolt (8) are clean and
dry. Apply Tooling (E) to the threads of the bolt.
Install bolt (8). Tighten the bolt to a torque of
26 Nm (19 lb ft).
8. Check the end play of idler gear (10). Refer to
Specifications, Engine Oil Pump.
9. Install the engine oil relief valve . Refer to
Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install for further information.

Illustration 196

g01252312

3. Install Tooling (G) to the cylinder block.

Installation Procedure
Table 56

Required Tools
Tool

Part Number

27610211

Crankshaft Timing Pin

27610225

Timing Pin (Balancer)

21825617

Dial Indicator Group

Finger Clock

Guide Studs
(M10 by 75 mm)

F
G

Part Description

Qty

Illustration 197

g01260306

4. Ensure that dowels (6) and (7) are seated in the

housing of balancer (1).

KENR6247

97
Disassembly and Assembly Section

12. Install bolts (3). Tighten the bolts to a torque to

22 Nm (16 lb ft).
13. Use Tooling (F) in order to check the backlash
between gears (10) and (13). Refer to Illustration
197. Refer to Specifications, Engine Oil Pump.
14. Use Tooling (F) in order to check the backlash
between gear (10) and the crankshaft gear. Refer
to Specifications, Gear Group - Front for further
information.
End By:
Illustration 198

g01252310

5. Install Tooling (C) to balancer (1). Ensure that

Tooling (C) is engaged into shaft (5).
6. Attach a suitable lifting device to the balancer. The
balancer weighs approximately 23 kg (51 lb).

a. Install the engine oil pan. Refer to Disassembly

and Assembly , Engine Oil Pan - Remove and
Install.
b. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
i02628896

7. Use the lifting device to align balancer (1) with

Tooling (G). Install the balancer to the cylinder
block. Ensure that dowels (6) and (7) are aligned
with the holes in the cylinder block. Ensure that
gear (10) and the crankshaft gear mesh. Remove
the lifting device.

Piston Cooling Jets - Remove

and Install
Removal Procedure
Table 57

Required Tools
Tool

Part
Number

Part Description

Qty

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

A2

Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.
Illustration 199

g01259635

8. Install bolts (4) to balancer (1) finger tight.

9. Remove the Tooling (G) and install the remaining
bolts (4). Tighten the bolts to a torque of 54 Nm
(40 lb ft).
10. Remove the Tooling (B) and (C).
11. Install suction pipe (2) and a new joint to balancer
(1).

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

98
Disassembly and Assembly Section

KENR6247

1. If the crankshaft is installed, use Tooling (A) to

rotate the crankshaft in order to gain access to the
piston cooling jet.

Illustration 201

g01265615

Illustration 200
Typical example

2. Remove bolt (1) and piston cooling jet (2) from

the cylinder block.
3. Repeat Steps 1 and 2 for the remaining piston
cooling jets.

Installation Procedure
Table 58

1. Clean the piston cooling jets and inspect the

piston cooling jets for damage. Ensure that the
valve is free to move within each piston cooling
jet. Replace any damaged piston cooling jets.
2. If the crankshaft is installed, use Tooling (A)
to rotate the crankshaft in order to access the
mounting flange for the piston cooling jet.
3. Position piston cooling jet (2) in the cylinder block.
Install bolt (1). Tighten the bolt to a torque of
9 Nm (80 lb in).
4. Repeat Steps 2 through 3 for the remaining piston
cooling jets.

Required Tools
Tool

Part
Number

Part Description

Qty

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

A2

g01265615

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

5. If the cylinder head has been removed, It is

possible to check the alignment of the piston
cooling jets. Refer to Specifications, Piston
Cooling Jet Alignment for more information.
Note: It is not possible to check the alignment of the
piston cooling jets with the cylinder head in position.
End By:
a. If the engine is equipped with a balancer, install
the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.

KENR6247

99
Disassembly and Assembly Section

i02628900

Pistons and Connecting Rods

- Remove
Removal Procedure
Table 59

Required Tools
Tool

Part Number

Part Description

Qty

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610274

Ridge Reamer

A2
B

Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly , Cylinder Head - Remove.

Illustration 202

g01344569

b. If the engine is equipped with a balancer, remove

the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.

3. The connecting rod and the connecting rod cap

should have an etched number (X) on the side.
The number on the connecting rod and the
connecting rod cap must match. Ensure that the
connecting rod and connecting rod cap (2) are
marked for the correct location. If necessary, make
a temporary mark on the connecting rod and the
connecting rod cap in order to identify the cylinder
number.

c. Remove the piston cooling jets. Refer to

Disassembly and Assembly , Piston Cooling Jets
- Remove and Install.

Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly
could cause the connecting rod to fracture.

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.

4. Remove bolts (1) and remove connecting rod cap

(2) from the connecting rod.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Use Tooling (A) to rotate the crankshaft until the
crank pin is at the bottom center position.
2. Use Tooling (B) to remove the carbon ridge from
the top inside surface of the cylinder bore.

Illustration 203

g01244066

Typical example

5. Carefully push piston (3) and the connecting rod

assembly out of the cylinder bore. Lift the piston
out of the top of the cylinder block.
Note: Do not push on the fracture split surfaces of
the connecting rod as damage may result.

100
Disassembly and Assembly Section

KENR6247

6. Temporarily install connecting rod cap (2) and

bolts (1) to the connecting rod when the assembly
is out of the engine. Tighten bolts (1) to a torque
of 20 Nm (14 lb ft).
Note: Fracture split connecting rods should not be left
without the connecting rod caps installed. Ensure that
the etched number on connecting rod cap matches
the etched number on connecting rod. Ensure the
correct orientation of the connecting rod cap.
7. Repeat Steps 1 through 5 for the remaining
pistons and connecting rods.
i02628898

Pistons and Connecting Rods

- Disassemble
Disassembly Procedure
Table 60

Required Tools
Tool

Part
Number

Circlip Pliers

Piston Ring Expander

Part Description

Qty

Illustration 204

g01244067

Illustration 205

g01253091

Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Remove.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Make a temporary mark on the components of
the piston and connecting rod assembly. This
will ensure that the components of each piston
and connecting rod assembly can be reinstalled
in the original cylinder. Mark the underside of the
piston on the front pin boss. Do not interchange
components.

Typical example

KENR6247

101
Disassembly and Assembly Section

2. Place the piston and connecting rod assembly on

a suitable surface with the connecting rod upward.
Use Tooling (A) in order to remove retaining
rings(5).
Note: The forged marks (X) identify the front of the
connecting rod assembly. The forged marks should
be used for the purposes of orientation.

NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distributor.

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

piston (4).

7. Inspect the connecting rod for wear or damage. If

necessary, replace connecting rod (6) or replace
bush (7) for the piston pin.

Note: If the piston pin cannot be removed by hand,

heat the piston to a temperature of 45 5 C
(113 9 F). Do not use a torch to heat the piston.
Note the orientation of the connecting rod and the
piston.

Note: If the connecting rod or the bush for the piston

pin are replaced, first identify the height grade of the
connecting rod. Refer to Specifications, Connecting
Rod.

4. Place the piston on a suitable surface with the

crown upward. Use Tooling (B) in order to remove
compression rings (1) and (2), and oil control ring
(3) from piston (4).
Note: Identify the position and orientation of
compression rings (1) and (2), and oil control ring (3).

8. Repeat Steps 1 through 7 in order to disassemble

the remaining pistons and connecting rods.
i02628897

Pistons and Connecting Rods

- Assemble
Assembly Procedure
Table 61

Required Tools

Illustration 206

g01244068

5. Remove bolts (12) and connecting rod cap (11)

from connecting rod (6). Discard the bolts.
Note: Fracture split connecting rods should not be left
without the connecting rod caps installed. After the
disassembly procedure for the piston and connecting
rod is completed, carry out the assembly procedure
and the installation procedure as soon as possible.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Assemble and Disassembly and
Assembly, Piston and Connecting Rods - Install.
6. Remove the lower half of connecting rod bearing
(10) from connecting rod cap (11). Remove the
upper half of connecting rod bearing (9) from
connecting rod (6). Keep the bearing shells
together.

Tool

Part
Number

Circlip Pliers

Piston Ring Expander

Part Description

Qty

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that all components are clean and free
from wear or damage. If necessary, replace any
components that are worn or damaged.
2. If the original piston is assembled, follow Steps
2.a through 2.e in order to install the piston rings.
a. Position the spring for oil control ring (3) into
the oil ring groove in piston (4). The central wire
must be located inside the end of the spring.

102
Disassembly and Assembly Section

Illustration 207

KENR6247

g01155119

b. Use Tooling (B) to install oil control ring (3) over

the spring.
Note: Ensure that the central wire is 180 degrees
from the ring gap.
c. Use Tooling (B) to install intermediate
compression ring (2) into the second groove in
piston (4). The word TOP must be upward.
The chamfer on the inner face must be
downward.
d. Use Tooling (B) to install top compression ring
(1) into the top groove in piston (4). The word
TOP must be upward.

Illustration 208

g01244067

4. Lubricate bush (7) and lubricate the bore for the

piston pin in piston (4) with clean engine oil.

e. Position the piston ring gaps at 120 degrees

away from each other.
Note: A new piston assembly is supplied with new
piston rings.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distributor.
3. If the connecting rod assembly or the bush for
the piston pin have been replaced, ensure that
the height grade of the connecting rod is correct.
Refer to Specifications, Connecting Rod for
further information.

Illustration 209

g01244172

5. Place the piston on a suitable surface with the

crown downward. Install connecting rod (6) and
piston pin (8) to piston (4). Ensure that square
boss (13) on the piston, and forged mark (X) on
the connecting rod are in the correct position. See
illustration 209.
Note: If the piston pin cannot be installed by hand,
heat the piston to a temperature of 45 5C
(113 9F).

KENR6247

103
Disassembly and Assembly Section

6. Use Tooling (A) in order to install retaining rings

(5) to the piston pin bore in piston (4).
Note: Ensure that the retaining rings are seated in
the grooves in the piston.

Note: Fracture split connecting rods should not be

left without the connecting rod caps installed. After
the assembly procedure for the piston and connecting
rod is completed, carry out the installation procedure
as soon as possible. Refer to Disassembly and
Assembly, Piston and Connecting Rods - Install.
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Install.
i02628899

Pistons and Connecting Rods

- Install
Illustration 210

g01244068

Installation Procedure
Table 62

Required Tools
Tool

Part
Number

Part Description

Qty

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

21825491

Piston Ring Compressor

21825607

Angle gauge

A2

Illustration 211

g01001160

Aligning the connecting rod bearing in the center of the connecting

rod

Note: New connecting rod bearings are supplied with

an alignment tool. If new connecting rod bearings
are installed, use the tool to align the bearing in the
connecting rod.
7. Install the upper half of connecting rod bearing
(9) to connecting rod (6). Ensure that the bearing
is centralized in the connecting rod. Refer to
Illustration 211.
8. Install the lower half of connecting rod bearing
(10) to connecting rod cap (11). Ensure that the
bearing is centralized in the connecting rod cap.
Refer to Illustration 211.
9. Repeat Steps 2 through 8 for the remaining piston
and connecting rod assemblies.

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Discard all used connecting rod bolts.
1. If the connecting rod caps were temporarily
installed, remove the connecting rod caps. If
necessary, thoroughly clean all of the components.
2. Apply clean engine oil to the cylinder bore, to the
piston rings, to the outer surface of the piston and
to the connecting rod bearings.

104
Disassembly and Assembly Section

KENR6247

Note: Install the connecting rod bearings dry

when clearance checks are performed. Refer to
Disassembly and Assembly, Bearing Clearance Check. Apply clean engine oil to the connecting rod
bearings during final assembly.
3. Use Tooling (A) to rotate the crankshaft until the
crankshaft pin is at the bottom center position.
Lubricate the crankshaft pin with clean engine oil.

Illustration 213

g01344572

Typical example
Illustration 212

g01253096

Typical example

4. Ensure that the gaps for the piston rings are at

120 degrees away from each other. Install Tooling
(B) onto piston (3).
Note: Ensure that Tooling (B) is installed correctly
and that the piston can easily slide from the tool.
Ensure that the piston and the connecting rod
assembly are installed in the correct cylinder. The
arrow on the top of the piston must be toward the
front of the engine.

6. Install connecting rod cap (2) onto the connecting

rod.
Note: Ensure that etched number (X) on the
connecting rod cap matches the etched number on
the connecting rod. Ensure the correct orientation of
connecting rod cap (2).
7. Install new bolts (1) to the connecting rod. Tighten
the bolts evenly to a torque of 18 Nm (13 lb ft).
8. Tighten the bolts evenly to a torque of 70 Nm
(52 lb ft).

5. Carefully push the piston and the connecting rod

assembly into the cylinder bore and onto the
crankshaft pin.

9. Use Tooling (B) to turn the bolts through an

additional 120 degrees.

Note: Do not damage the finished surface of the

crankshaft pin.

10. Ensure that the installed connecting rod assembly

has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
11. Repeat Steps 2 through 10 in order to install the
remaining pistons and connecting rods.
Note: If all pistons and connecting rods require
replacement the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders. 1
with 4 and 2 with 3. Ensure that both pairs of the
pistons and connecting rods are installed before
changing from one pair of cylinders to another
pair of cylinders..

KENR6247

105
Disassembly and Assembly Section

12. Check the height of the pistons above the top face
of the cylinder block. Refer to Systems Operation,
Testing and Adjusting, Piston Height - Inspect for
the correct procedure.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, Piston Cooling Jets - Remove
and Install.
b. If the engine is equipped with a balancer, install
the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.
c. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02628814

Connecting Rod Bearings Remove

(Connecting rods in position)

NOTICE
Discard all used connecting rod bolts.
Note: If all connecting rod bearings require
replacement the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed
before changing from one pair of cylinders to
another pair of cylinders.. Refer to Disassembly
and Assembly, Connecting Rod Bearings - Install.
1. Use Tooling (A) to rotate the crankshaft until the
crank pin is at the bottom center position.
If necessary, remove the glow plugs. Refer
to Disassembly and Assembly, Glow Plugs Remove and Install.
Note: Removal of the glow plugs aids removal of the
connecting rod bearings. It is not essential.

Removal Procedure
Table 63

Required Tools
Tool

Part Number

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

A2

Part Description

Qty

Start By:
a. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.

Illustration 214

g01344569

Illustration 215

g01253101

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

106
Disassembly and Assembly Section

KENR6247

2. The connecting rod and the connecting rod cap

should have an etched number (X) on the side.
The number on the connecting rod and the
connecting rod cap must match. If necessary,
make a temporary mark on connecting rod (5)
and connecting rod cap (2) in order to identify the
cylinder number.
Note: Do not punch identification marks onto fracture
split connecting rods. Do not stamp identification
marks onto fracture split connecting rods.
3. Remove bolts (1) and connecting rod cap (2) from
connecting rod (5). Discard the bolts.
4. Remove the lower half of connecting rod bearing
(3) from connecting rod cap (2). Keep the
connecting rod bearing and the connecting rod
cap together.
5. Carefully push the piston and connecting rod
assembly into the cylinder bore until connecting
rod (5) is clear of the crankshaft. Remove the
upper half of connecting rod bearing (4) from
connecting rod (5). Keep the bearings together.

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Discard all used connecting rod bolts.
1. Inspect the pins of the crankshaft for damage.
If the crankshaft is damaged, replace the
crankshaft or recondition the crankshaft. Refer
to Disassembly and Assembly, Crankshaft
- Remove and Disassembly and Assembly,
Crankshaft - Install. Ensure that the connecting
rod bearings are clean and free from wear or
damage. If necessary, replace the connecting rod
bearings.

Note: Do not push on the fracture split surfaces of the

connecting rod as damage may result. Do not allow
the connecting rod to contact the piston cooling jet.
Fracture split connecting rods should not be left
without the connecting rod caps installed. After the
removal procedure for the connecting rod bearings
is complete, carry out the installation procedure
as soon as possible. Refer to Disassembly and
Assembly, Connecting Rod Bearings - Install.
i02744541

Illustration 216

g01260354

g01001160

Connecting Rod Bearings Install

(Connecting rods in position)
Installation Procedure
Table 64

Required Tools
Tool

Part Number

21825576

Crankshaft Turning Tool

Illustration 217

27610291

Barring Device Housing

Aligning the bearing in the center of the connecting rod

27610289

Gear

21825607

Angle Gauge

Note: New connecting rod bearings are supplied with

an alignment tool. If new bearings are installed, use
the tool to align the bearing in the connecting rod.

A2
B

Part Description

Qty

KENR6247

107
Disassembly and Assembly Section

2. Install the upper half of connecting rod bearing

(4) to connecting rod (5). Ensure that the bearing
is centralized in the connecting rod. Refer to
Illustration 217.
The ends of the bearing must be centered in the
connecting rod. The ends of the bearing must be
equally positioned in relation to the mating faces
of the connecting rod.
3. Clean the connecting rod cap. Install lower
connecting rod bearing (3) to connecting rod cap
(2). Ensure that the connecting rod bearing is
centralized in the connecting rod cap. Refer to
Illustration 217.
The ends of the lower connecting rod bearing
must be centered in the connecting rod cap. The
ends of the lower connecting rod bearing must be
equally positioned in relation to the mating faces
of the connecting rod cap.
4. Lubricate upper connecting rod bearing (4) with
clean engine oil.
5. If necessary, use Tooling (A) in order to rotate the
crankshaft until the crankshaft pin is at the bottom
dead center position.

Note: Ensure that etched number (X) on connecting

rod cap (2) matches etched number (X) on
connecting rod (5). Ensure the correct orientation of
the connecting rod cap. The forged marks (Y) on the
connecting rod and the connecting rod cap should be
on the same side. Refer to Illustration 216.
9. Install new bolts (1). Tighten the bolts evenly to a
torque of 18 Nm (13 lb ft).
Note: Do not reuse the old bolts in order to secure
the connecting rod cap.
10. Tighten the bolts evenly to a torque of 70 Nm
(52 lb ft).
11. Use Tooling (B) to turn the bolts through an
additional 120 degrees.
12. Ensure that the installed connecting rod assembly
has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
13. Repeat Steps 2 through 12 for the remaining
connecting rod bearings.

Note: Do not allow the connecting rod to contact the

piston cooling jet.

Note: If all connecting rod bearings require

replacement the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that both pairs of
the connecting rod bearings are installed before
changing from one pair of cylinders to another
pair of cylinders..

7. Lubricate the pin of the crankshaft and lubricate

lower connecting rod bearing (3) with clean engine
oil.

14. If the glow plugs were removed, install the glow

plugs. Refer to Disassembly and Assembly, Glow
Plugs - Remove and Install.

6. Carefully pull connecting rod (5) against the

crankshaft pin.

End By:
a. If the engine is equipped with a balancer, install
the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.

Illustration 218

g01344572

8. Install connecting rod cap (2) to connecting rod

(5).

108
Disassembly and Assembly Section

KENR6247

i02628821

Crankshaft Main Bearings Remove and Install

(Crankshaft in position)
Removal Procedure
Table 65

Required Tools
Tool

Part Number

Part Description

Qty

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

A2

Start By:

Illustration 219

g01253717

Typical example

1. Remove allen head screws (1). Remove bridge

piece (2).
2. Ensure that the main bearing cap is marked for
the correct location and orientation.

a. If the engine is equipped with a balancer, remove

the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.
b. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Remove.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
NOTICE
This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are removed.

Illustration 220

g01253719

Typical example

3. Remove bolts (3). Remove main bearing cap (4)

from the cylinder block.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 221
Typical example

g01253146

KENR6247

109
Disassembly and Assembly Section

4. Remove lower main bearing (5) from main bearing

cap (4). Keep the main bearing and the main
bearing cap together. Take care not to displace
dowels (6).
Note: The lower main bearing is a plain bearing that
has no oil holes. The dowels may remain in the main
bearing cap or in the cylinder block.

g01253145

Illustration 224

7. Push out upper main bearing (9) with a suitable

tool from the side opposite the locating tab.
Carefully rotate the crankshaft while you push on
the bearing . Remove upper main bearing (9) from
the cylinder block. Keep the bearings together.
Illustration 222

g01253137

Typical example

5. For number three main bearing cap, remove thrust

washers (7).

Note: Do not damage the machined surfaces of the

crankshaft during removal of the upper main bearing.
The upper main bearing has a groove and two oil
holes.

Installation Procedure
Table 66

Required Tools

Illustration 223

g01253142

Typical example

6. For number three main bearing, remove thrust

washers (8) from the cylinder block. In order to
remove the thrust washers, push the crankshaft
toward the front of the engine or push the
crankshaft toward the rear of the engine. Use
Tooling (A) in order to rotate the crankshaft. If
necessary, use a suitable tool to free the thrust
washers.
Note: Do not damage the machined surfaces of the
crankshaft during removal of the thrust washers.

Tool

Part
Number

21825617

Part Description

Qty

Dial Indicator Group

Straight Edge

5 mm Allen Socket

21826038

POWERPART
Silicon Rubber Sealant

NOTICE
This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are removed.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

110
Disassembly and Assembly Section

KENR6247

1. Ensure that the main bearings are clean and free

from wear or damage. If necessary, replace the
main bearings.
2. Clean the journals of the crankshaft. Inspect
the journals of the crankshaft for damage. If
necessary, replace the crankshaft or recondition
the crankshaft.

Illustration 227

g01253146

Typical example

5. Install lower main bearing (5) into main bearing

cap (4). Ensure that the locating tab for the lower
main bearing is correctly seated into the slot in
the bearing cap.
Illustration 225

g01253145

Typical example

Note: The lower main bearing is a plain bearing that

has no oil holes.

3. Lubricate the crankshaft journal and the upper

main bearing (9) with clean engine oil. Slide the
upper main bearing (9) into position between the
crankshaft journal and the cylinder block. Ensure
that the locating tab for the upper main bearing is
correctly seated in the slot in the cylinder block.
Note: The upper main bearing has a groove and two
oil holes.

Illustration 228

g01253137

Typical example

Illustration 226

g01261200

Typical example

4. For number three main bearing, ensure that thrust

washers (8) are clean and free from wear or
damage. If necessary, replace the thrust washers.
Lubricate thrust washers (8) with clean engine oil.
Slide the thrust washers into position between the
crankshaft and the cylinder block. The grooves in
the thrust washers must be located against the
crankshaft.

6. For number three main bearing cap, ensure that

thrust washers (7) are clean and free from wear or
damage. If necessary, replace the thrust washers.
Lubricate thrust washers (7) with clean engine
oil. Place the thrust washers into position on the
main bearing cap. Ensure that the locating tab is
correctly seated in the main bearing cap.

KENR6247

111
Disassembly and Assembly Section

11. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
crankshaft end play. The permissible crankshaft
end play is 0.17 mm (0.007 inch) to 0.41 mm
(0.016 inch).

Illustration 229

g01253719

Typical example

7. Lubricate the crankshaft journal and the lower

main bearing with clean engine oil. Install main
bearing cap (4) to the cylinder block.
Note: Ensure the correct orientation of the main
bearing cap. The locating tab for the upper and the
lower bearing should be on the same side of the
engine.
8. Lubricate the threads of bolts (3) with clean engine
oil. Lubricate the underside of the heads of the
bolts with clean engine oil.
9. Install bolts (3) to main bearing cap (4). Evenly
tighten the bolts in order to pull cap (5) into
position. Ensure that the cap is correctly seated.
Note: Do not tap the main bearing cap into position
as the bearing may be dislodged.
10. Tighten bolts (3) to a torque of 245 Nm (180 lb ft).

Illustration 231

g01253836

Typical example

12. Follow Steps 12.a through 12.d in order to install

the bridge piece.
a. Ensure that the recess in the cylinder block
and the bridge piece are clean, dry and free
from old sealant.
b. Install bridge piece (2) and allen head screws
(1). Tighten the allen head screws finger tight.
c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
cylinder block.
d. Use Tooling (D) to tighten allen head screws
(1) to a torque of 16 Nm (12 lb ft).
13. Install the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Install.

Illustration 230
Typical example

g01253186

Illustration 232
Typical example

g01344584

112
Disassembly and Assembly Section

KENR6247

14. Apply Tooling (E) to cavities (Y) in bridge piece

(2). Continue to apply Tooling (E) until sealant
extrudes from cavities (X).

NOTICE
Keep all parts clean from contaminants.

Note: If the oil pan will not be installed immediately,

ensure that the joint face of the bridge piece. and the
cylinder block are left free of sealant.

Contaminants may cause rapid wear and shortened

component life.

End By:

1. The engine should be mounted on a suitable

stand and placed in the inverted position.

a. If the engine is equipped with a balancer, install

the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.

2. If necessary, remove the cylinder head. Refer

to Disassembly and Assembly, Cylinder Head Remove. Remove the pistons and connecting
rods. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Remove.

i02628818

Crankshaft - Remove

If the cylinder head, the pistons and the

connecting rods have not been removed, remove
the connecting rod caps. Refer to Disassembly
and Assembly, Connecting Rod Bearings Remove.

Removal Procedure
Table 67

Required Tools
Tool

Part
Number

Part Description

Qty

Lifting Strap

Start By:
a. Remove the rocker shaft and pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.

Illustration 233

b. Remove the front housing. Refer to Disassembly

and Assembly, Housing (Front) - Remove.

3. Remove allen head screws (1). Remove bridge

piece (2).

c. Remove the crankshaft rear seal. Refer to

Disassembly and Assembly, Crankshaft Rear
Seal - Remove.

4. Ensure that the bearing caps are marked for the

location and orientation.

d. If the engine is equipped with a balancer, remove

the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.

g01253717

Typical example

KENR6247

113
Disassembly and Assembly Section

Note: The lower bearings are plain bearings that

have no oil holes. The dowels may remain in the
bearing cap or in the cylinder block.

Illustration 234

g01253719

Typical example

5. Remove bolts (3) and bearing caps (4) from the

cylinder block.

Illustration 237

g01254099

Typical example

7. Attach Tooling (A) and a suitable lifting device to

crankshaft (8). Carefully lift the crankshaft out of
the cylinder block. The weight of the crankshaft is
approximately 30 kg (66 lb).
Note: Do not damage any of the finished surfaces
on the crankshaft, when the crankshaft is removed
from the engine.

Illustration 235

g01253146

Typical example

Illustration 238

g01254104

Typical example

8. Remove upper bearings (9) from the cylinder

block. Keep the upper bearings with the respective
bearing caps.
Illustration 236

g01253137

Typical example

6. Remove lower bearings (5) from bearing caps (4).

Take care not to displace dowels (6). For number
three bearing cap, remove thrust washers (7).
Keep the lower bearing and the thrust washers
with the respective bearing caps.

Note: The upper bearings have a groove and two

oil holes.
9. Remove thrust washers (10) from number three
bearing in the cylinder block.
10. If necessary, remove the crankshaft gear. Refer
to Disassembly and Assembly, Crankshaft Gear
- Remove and Install.

114
Disassembly and Assembly Section

KENR6247

i02628817

Crankshaft - Install

Note: If the crankshaft bearings are replaced, check

whether oversize bearings were previously installed.
If the thrust washers are replaced, check whether
oversize thrust washers were previously installed.

Installation Procedure
Table 68

Required Tools
Tool

Part Number

21825617

Part Description

Qty

Lifting Strap

Dial Indicator Group

Straight Edge

5 mm Allen Socket

21826038

POWERPART
Silicon Rubber Sealant

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.

Illustration 239

g01253240

Typical example

5. Install upper bearings (9) to the cylinder block.

Ensure that the locating tabs for the upper
bearings are seated in the slots in the cylinder
block.
Note: The upper bearings have a groove and two
oil holes.
6. Lubricate upper bearings (9) with clean engine oil.

1. Clean the crankshaft and inspect the crankshaft

for wear or damage. Refer to Specifications,
Crankshaft for more information. If necessary,
replace the crankshaft or recondition the
crankshaft.
2. If necessary, install the crankshaft gear. Refer to
Disassembly and Assembly, Crankshaft Gear Remove and Install.
g01254099

Note: The engine should be mounted on a suitable

stand and placed in the inverted position.

Illustration 240

3. Ensure that the parent bores for the crankshaft

bearings in the cylinder block are clean. Ensure
that the threads for the bearing bolts in the cylinder
block are clean and free from damage.

7. Attach Tooling (A) and a suitable lifting device to

crankshaft (8). Carefully lift the crankshaft into
the cylinder block. The weight of the crankshaft is
approximately 30 kg (66 lb). Remove Tooling (A).

4. Clean the crankshaft bearings and the thrust

washers. Inspect the bearings and the thrust
washers for wear or damage. If necessary, replace
the bearings and the thrust washers.

Note: Do not damage any of the finished surfaces on

the crankshaft. Do not damage the bearing.

Typical example

KENR6247

115
Disassembly and Assembly Section

9. Install lower bearings (5) into bearing caps (4).

Ensure that the locating tabs for the lower bearings
are correctly seated into the slots in the bearing
caps. For number three bearing cap, ensure that
thrust washers (7) are clean and free from wear
or damage. If necessary, replace both the thrust
washers. Lubricate thrust washers (7) with clean
engine oil. Place the thrust washers into position
on the bearing cap. Ensure that the locating tab is
correctly seated in the bearing cap.
Note: The lower bearing is a plain bearing that has
no oil holes.
Illustration 241

g01254100

Typical example

8. For number three bearing, ensure that thrust

washers (10) are clean and free from wear or
damage. If necessary, replace the thrust washers.
Lubricate thrust washers (10) with clean engine
oil. Slide the thrust washers into position between
the crankshaft and the cylinder block.

10. Lubricate lower bearings (5) and lubricate the

journals of crankshaft (8) with clean engine oil.
Install bearing caps (4) to the cylinder block.
Note: Ensure the correct location and orientation of
the bearing caps. The locating tabs for the upper
and the lower bearings should be on the same side
of the engine.

Note: The grooves in the thrust washers must be

located against the crankshaft.

Illustration 244

Illustration 242

g01253146

g01253719

11. Lubricate the threads of bolts (3) with clean

engine oil. Lubricate the underside of the heads
of the bolts with clean engine oil.
12. Install bolts (3) to bearing caps (4). Evenly tighten
the bolts in order to pull the caps into position.
Ensure that the caps are correctly seated.
Note: Do not tap the bearing caps into position as
the bearing may be dislodged.
13. Tighten bolts (3) to a torque of 245 Nm (180 lb ft).
14. Rotate the crankshaft in order to ensure that there
is no binding.

Illustration 243

g01253137

116
Disassembly and Assembly Section

KENR6247

Illustration 246

g01254102

Typical example

18. Follow Steps 18.a through 18.d in order to install

the bridge piece.
Illustration 245

g01253186

Typical example

15. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
crankshaft end play. The permissible crankshaft
end play is 0.17 mm (0.007 inch) to 0.41 mm
(0.016 inch).
16. If the piston and connecting rods have been
removed , install the piston and connecting rods.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Install.

a. Ensure that the cylinder block and the bridge

piece are clean, dry and free from old sealant.
b. Install bridge piece. (2) and allen head screws
(1). Tighten the allen head screws finger tight.
c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
cylinder block.
d. Use Tooling (D) in order to tighten the allen
head screws to a torque of 16 Nm (12 lb ft).
19. Install the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Install.

If the piston and connecting rods have not been

removed , install the connecting rod caps. Refer
to Disassembly and Assembly, Connecting Rod
Bearings - Install.
17. If the crankshaft has been replaced or the
crankshaft has been reconditioned, inspect the
height of the piston above the cylinder block. Refer
to Systems Operation, Testing and Adjusting,
Piston Height - Inspect for more information.

Illustration 247

g01344593

Typical example

20. Apply Tooling (E) to cavities (Y) in the bridge

piece (2). Continue to apply Tooling (E) until
sealant extrudes from cavities (X).

KENR6247

117
Disassembly and Assembly Section

Note: If the oil pan will not be installed immediately,

ensure that the joint face of the bridge piece and the
cylinder block are left free of sealant.
End By:
a. If the engine has a balancer, install the balancer.
Refer to Disassembly and Assembly, Balancer Install. If the engine does not have a balancer,
install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: The crankshaft gear may be a sliding fit on the
crankshaft or an interference fit on the crankshaft.

b. Install the front housing. Refer to Disassembly and

Assembly, Housing (Front) - Install.
c. If necessary, install the cylinder head. Refer to
Disassembly and Assembly, Cylinder Head Install.
d. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, Rockershaft and
Push Rods - Install.
i02628820

Crankshaft Gear - Remove and

Install

Illustration 248

g01367358

Typical example

Removal Procedure
Table 69

Required Tools
Tool

Part
Number

Part Description

Qty

Bearing Puller

Puller

Crossblock

Puller Leg

Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.

Illustration 249

g01270549

Typical example

b. If the engine is equipped with a balancer, remove

the balancer. Refer to Disassembly and Assembly,
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, Engine Oil
Pump - Remove.

1. If the crankshaft gear is a sliding fit on the

crankshaft, remove crankshaft gear (1) from
crankshaft (2).
If the crankshaft gear is an interference fit on the
crankshaft, use Tooling (A) in order to remove
crankshaft gear (1) from crankshaft (2).
2. If necessary, remove key (3) from crankshaft (2).
Note: Do not remove the key from the crankshaft
unless the key is damaged.

118
Disassembly and Assembly Section

KENR6247

Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

b. If the engine is equipped with a balancer, install

the balancer. Refer to Disassembly and Assembly,
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, Engine Oil Pump
- Install.
i02748526

1. Ensure that all components are clean and free

from wear or damage. If necessary, replace any
components that are worn or damaged.

Bearing Clearance - Check

Measurement Procedure
Table 70

Required Tools
Tool

Illustration 250

g01367359

Typical example

Part
Number

Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing
or protective equipment to protect your skin.
3. If the crankshaft gear is a sliding fit on the
crankshaft, align the keyway in crankshaft gear (1)
with key (3) in the crankshaft. Install crankshaft
gear (1) to crankshaft (2).
If the crankshaft gear is an interference fit on the
crankshaft, heat crankshaft gear (1) in an oven to
150 50C (302 90F). Align the keyway in
crankshaft gear (1) with key (3) in the crankshaft.
Install crankshaft gear (1) to crankshaft (2).
Ensure that shoulder (4) on crankshaft gear (1) is
toward the front of the engine.
End By:
a. Install the front housing. Refer to Disassembly and
Assembly Manual, Housing (Front) - Install.

Qty

Plastic Gauge (Green)

0.025 to 0.076 mm
(0.001 to 0.003 inch)

Plastic Gauge (Red)

0.051 to 0.152 mm
(0.002 to 0.006 inch)

Plastic Gauge (Blue)

0.102 to 0.229 mm
(0.004 to 0.009 inch)

Plastic Gauge (Yellow)

0.230 to 0.510 mm
(0.009 to 0.020 inch)

2. If necessary, install a new key (3) to crankshaft (2).

Note: The crankshaft gear may be a sliding fit on the
crankshaft or an interference fit on the crankshaft.

Part Description

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Perkins does not recommend the checking of
the actual clearances of the bearing shells particularly
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the
bearing shell or the journal surfaces. Each Perkins
bearing shell is quality checked for specific wall
thickness.
Note: The measurements should be within
specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).

KENR6247

119
Disassembly and Assembly Section

NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
The technician must be very careful to use Tooling (A)
correctly. The following points must be remembered:

Note: When Tooling (A) is used, the readings can

sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, Connecting Rod Bearing Journal and
Specifications Manual, Main Bearing Journal for the
correct clearances.

Ensure that the backs of the bearings and the

bores are clean and dry.

Ensure that the bearing locking tabs are properly

seated in the tab grooves.

i02628884

Glow Plugs - Remove and

Install

The crankshaft must be free of oil at the contact

points of Tooling (A).

1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the
edge of the bearing.
2. Use the correct torque-turn specifications in order
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A)
is installed.
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 251.

Illustration 251

g01152855

Typical Example

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

bearing cap.

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Isolate the electrical supply.
2. If the engine is equipped with a cover over the fuel
injectors remove the cover. Refer toDisassembly
and Assembly, Fuel Injector Cover - Remove and
Install.
3. Remove the breather tube from the valve
mechanism cover. Refer toDisassembly and
Assembly, Crankcase Breather- Remove and
Install.

120
Disassembly and Assembly Section

KENR6247

g01346250

Illustration 252

Illustration 253

g01346250

Typical example

Typical example

4. Disconnect harness assembly from bus bar (1).

2. Install glow plugs (3) into the cylinder head.

Tighten the glow plugs to a torque of 15 Nm
(132 lb in).

5. Remove nuts (2) that secure bus bar (1) to glow

plugs (3).
6. Remove bus bar (1) from glow plugs (3).
7. Remove glow plugs (3) from the cylinder head.

4. Connect harness assembly to bus bar (1).

Installation Procedure

5. Install the breather tube to the valve mechanism

cover. Refer toDisassembly and Assembly,
Crankcase Breather- Remove and Install.

Table 71

Required Tools
Tool

Part
Number

27610296

Part Name
Torque Wrench

3. Position bus bar (1) onto glow plugs (3). Install

nuts (2) onto the glow plugs. Use Tooling (A) in
order to tighten the nuts to a torque of 2 Nm
(17 lb in).

Qty
1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the threads of the glow plugs are clean
and free from damage. Replace any damaged
glow plugs.

6. If the engine is equipped with a cover over the fuel

injectors install the cover. Refer toDisassembly
and Assembly, Fuel Injector Cover - Remove and
Install.
7. Restore the electrical supply to the engine.

KENR6247

121
Disassembly and Assembly Section

i02628912

V-Belts - Remove and Install

(Engines Without an Automatic
Belt Tensioner )
Removal Procedure

Illustration 255

g01254466

Typical example

1. Install V-belts (3) onto the correct pulleys.

Note: Used V-belts should be installed in the original
position and direction of rotation.

g01254466

Illustration 254
Typical example

1. If the engine is equipped with fan guards, remove

the fan guards.

2. Adjust the tension on the V-belts by moving the

alternator away from the engine. Use Tooling
(A) in order to achieve the correct belt tension.
Refer to System Operation, Testing and Adjusting,
V-Belt -Test for more information. Tighten bolt (4)
to a torque of 22 Nm (16 lb ft).
3. Tighten bolt (2) to a torque of 44 Nm (32 lb ft).

2. Loosen nut (1), bolt (2) and bolt (4). Slide the
alternator toward the engine.

4. Tighten nut (1) to a torque of 22 Nm (16 lb ft).

3. Remove V-belts (3).

5. If the engine is equipped with fan guards, install

the fan guards.

Note: Mark the position and direction of rotation if the

V-belts will be reused. Never replace single V-belts.
Always replace V-belts as a pair.

Installation Procedure
Table 72

Required Tools
Tool

Part
Number

Part Description
Belt Tension Gauge

Qty
1

122
Disassembly and Assembly Section

KENR6247

i02589352

Alternator Belt - Remove and

Install
(Engines With an Automatic
Belt Tensioner)

Table 73

Part Description

Qty

Locking Pin
( 8mm by 85 mm)

Installation Procedure
Table 74

Required Tools

1. If the engine has fan guards, remove the fan

guards.

Illustration 256

7. If necessary, follow Steps 7.a and 7.b in order to

remove tensioner (3) from mounting bracket (2).

b. Remove tensioner (3) from mounting bracket

(2).

Required Tools
Part
Number

6. Release the pressure on the square drive tool and

remove the tool from hole (X).

a. Remove bolt (4) that secures tensioner (3) to

mounting bracket (2).

Removal Procedure

Tool

5. From the front of the engine, turn the square drive

tool in a clockwise direction. Release the pressure
on Tooling (A). Remove Tooling (A) from hole (Y).

Tool

Part
Number

Part Description
Locking Pin
( 8mm by 85 mm)

Qty
1

g01260739

Typical example

2. Install a suitable square drive tool into hole (X) in

tensioner (3). From the front of the engine, turn
the tool in a clockwise direction.
3. Insert Tooling (A) into hole (Y). Release the
pressure on the square drive tool.

Illustration 257

g01270907

Typical example

1. If the tensioner was previously removed, follow

Steps 1.a through 1.c in order to install the
tensioner.

4. Remove alternator belt (1).

a. Align the dowel in the back of tensioner (3) with

the hole in mounting bracket (2).

Note: Mark the direction of rotation if the belt will

be reused.

b. Install tensioner (3) to mounting bracket (2).

KENR6247

123
Disassembly and Assembly Section

c. Install bolt (4). Tighten the bolt to a torque of

45 5 Nm (33 3 lb ft).
2. Install a suitable square drive tool into hole (X) in
tensioner (1). From the front of the engine, turn
the tool in a clockwise direction.
3. Insert Tooling (A) into hole (Y). Release the
pressure on the square drive tool.
4. Install alternator belt (1). Ensure that the alternator
belt is centered on pulley (5). A used alternator
belt should be installed in the original direction of
rotation.
Note: The ribs on the alternator belt must be located
into the ribs of all pulleys.
5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
on Tooling (A). Remove Tooling (A) from hole (Y).
6. Release the pressure on the square drive tool until
the alternator belt is tensioned. Remove the tool
from hole (X).
Note: The tensioner should be at the nominal
position.
7. If the engine has fan guards, install the fan guards.

Illustration 258

g01270917

Typical example

1. Remove locking nuts (1).

2. Remove fan (2).
Note: Note the orientation of the fan.
3. Remove fan adapter (3).

i02628844

Fan - Remove and Install

Removal Procedure
Start By:
a. If the engine is equipped with an automatic belt
tensioner, remove the Alternator Belt. Refer to
Disassembly and Assembly, Alternator Belt Remove and Install. If the engine is not equipped
with an automatic belt tensioner, remove the
V-Belts. Refer to Disassembly and Assembly,
V-Belts - Remove and Install.

4. Remove fan pulley (4).

5. If necessary, remove studs (5) from fan drive (6).

Installation Procedure
1. Ensure that all the components are free from wear
or damage. If necessary, replace any components
that are worn or damaged.

124
Disassembly and Assembly Section

KENR6247

Illustration 260

g00944500

Typical example

1. Remove bolts (1) from fan drive (2).

Illustration 259

g01270917

Typical example

Note: Identify the orientation and the position of the

fan drive.
2. Remove fan drive (2).

2. If necessary, install studs (5) to fan drive (6).

Installation Procedure

3. Install fan pulley (4).

4. Install fan adapter (3).
5. Install fan (2).
Note: Ensure that the fan is correctly oriented.
6. Inspect the condition of locking nuts (1). If
necessary, replace the locking nuts. Install locking
nuts (1) and tighten to a torque of 22 Nm (16 lb ft).
End By:
a. If the engine is equipped with an automatic belt
tensioner, install the Alternator Belt. Refer to
Disassembly and Assembly, Alternator Belt Remove and Install. If the engine is not equipped
with an automatic belt tensioner, install the
V-Belts. Refer to Disassembly and Assembly,
V-Belts - Remove and Install.

Illustration 261

g00944500

Typical example

1. Check the fan drive for wear or damage. The fan

drive is not a serviceable item. If the fan drive is
worn or damaged, replace the fan drive.
2. Install fan drive (2).

i02628845

Fan Drive - Remove and Install

Note: Ensure the correct orientation of the fan drive.

3. Install bolts (1). Tighten the bolts to a torque of
44 Nm (32 lb ft).

Removal Procedure

End By:

Start By:

a. Install the fan. Refer to Disassembly and

Assembly, Fan - Remove and Install.

a. Remove the fan. Refer to Disassembly and

Assembly, Fan - Remove and Install.

KENR6247

125
Disassembly and Assembly Section

i02725803

Alternator - Remove
(Engines With an Automatic
Belt Tensioner)

a. Hold the shaft of alternator (3) with an allen

wrench. Use a cranked ring spanner (box
wrench) in order to loosen nut (7).
b. Remove nut (7) and pulley (8) from alternator
(1).
i02628804

Removal Procedure
Start By:
a. Remove the alternator belt. Refer to Disassembly
and Assembly, Alternator Belt - Remove and
Install.

Alternator - Remove
(Engines Without an Automatic
Belt Tensioner)
Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Start By:

Contaminants may cause rapid wear and shortened

component life.

a. Remove the V-belts. Refer to Disassembly and

Assembly, V-belts - Remove and Install.

1. Isolate the electrical supply to the engine.

NOTICE
Keep all parts clean from contaminants.

2. Make temporary identification marks on the

connections of the harness assembly.
Note: The incorrect connection of the harness
assembly can result in damage to the alternator or
failure.

Contaminants may cause rapid wear and shortened

component life.
1. Isolate the electrical supply to the engine.
2. Make temporary identification marks on the
connections of the harness assembly.

Illustration 262

g01271317

Typical example

3. Disconnect the harness assembly from alternator

(3).
4. Remove bolt (5) from alternator (3).
5. Remove nut (1) and washer (2). Remove bolt (6)
from alternator (3). Remove the alternator from
alternator bracket (4).
6. If necessary, follow Steps 6.a and 6 in order to
remove pulley (8) from alternator (1).

Illustration 263

g01255718

Typical Example

3. Disconnect the harness assembly from alternator

(1).

126
Disassembly and Assembly Section

KENR6247

4. Remove bolt (6) from alternator (4).

5. Remove nut (1) and washer (2). Remove bolt (5)
from alternator (4). Remove alternator (4) from
alternator bracket (3).
6. If necessary, remove pulley (8) from alternator (4).
Follow Steps 6.a and 6.b for the method in order
to remove the pulley from the alternator.
Note: This method may not be suitable for some
configurations of pulley.
a. Hold the shaft of alternator (4) with an allen
wrench. Use a cranked ring spanner (box
wrench) in order to loosen nut (7).
b. Remove nut (7) and pulley (8) from alternator
(4).
i02725802

Note: Different types of alternator have different

sizes of nut. Ensure that the correct torque value is
used for the nut.
Tighten M16 and M17 nuts to a torque of 80 Nm
(59 lb ft). Tighten 5/8 inch - 18 UNF nuts to a
torque of 102 Nm (75 lb ft).
2. Position alternator (3) on alternator mounting
bracket (4).
3. Install bolt (6) to alternator (3). Install washer (2)
and nut (1) to bolt (6).
4. Install bolt (5) to alternator (3).
5. Tighten nut (1) and bolt (5) to a torque of 22 Nm
(16 lb ft).
6. Connect the wiring harness assembly to alternator
(3).

Alternator - Install
(Engines With an Automatic
Belt Tensioner)

Note: The incorrect connection of the harness

assembly can result in damage to the alternator or
failure.

Installation Procedure

8. Restore the electrical supply.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.

Illustration 264

g01271317

Typical example

1. If necessary, install pulley (8) and nut (7) to

alternator (3). Hold the shaft of the alternator with
an allen wrench. Use a cranked ring spanner (box
wrench) in order to tighten nut (7).

7. Install the alternator belt. Refer to Disassembly

and Assembly, Alternator Belt - Remove and
Install.

KENR6247

127
Disassembly and Assembly Section

i02628802

Alternator - Install
(Engines Without an Automatic
Belt Tensioner)

6. Tighten nut (1) and bolt (6) to a torque of 22 Nm

(16 lb ft).
7. Connect the harness assembly to alternator (4).
8. Restore the electrical supply.
i02628831

Electric Starting Motor Remove and Install

Installation Procedure

Removal Procedure

Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative () battery terminal. Completely tape all metal surfaces of the
disconnected battery cable end in order to prevent
contact with other metal surfaces which could activate the engine electrical system.

Illustration 265

g01263045

Place a Do Not Operate tag at the Start/Stop switch

location to inform personnel that the equipment is
being worked on.

Typical example

1. If necessary, install the pulley to the alternator.

Follow Steps 1.a and 1.b for the method in order
to install the pulley to the alternator.
Note: This method may not be suitable for some
configurations of pulley.
a. Install pulley (8) and nut (7) to the shaft of
alternator (4).

1. Disconnect the battery.

2. If necessary, remove the hose for the crankcase
breather. Refer to Disassembly and Assembly,
Crankcase Breather - Remove.
3. Make temporary identification marks on the
harness assemblies that are connected to the
electric starting motor and to the solenoid.

b. Hold the shaft of the alternator with an allen

wrench. Use a cranked ring spanner (box
wrench) in order to tighten nut (7). Tighten the
nut to a torque of 80 Nm (59 lb ft).
2. Install alternator (4) to bracket (3) and install bolt
(5) to alternator (4).
3. Install washer (2) and nut (1) to bolt (5) finger tight.
4. Install bolt (6) through adjusting link (9) to
alternator (4) finger tight.
5. Install the V-belts. Refer to the Disassembly and
assembly, V-belts - Remove and Install for the
correct procedure.

Illustration 266

g01261155

Typical example

4. Disconnect the harness assemblies from the

electric starting motor and from the solenoid.

128
Disassembly and Assembly Section

KENR6247

5. Remove nuts (3) from electric starting motor (1).

Note: Support the weight of the electric starting
motor as the nuts are removed.

i02628801

Air Compressor - Remove and

Install

6. Remove electric starting motor (1).

7. If necessary, remove studs (2).

Removal Procedure

Installation Procedure

Table 75

Required Tools
Tool

Part
Number

A1

21825576

Crankshaft Turning Tool

27610291

Barring Device Housing

27610289

Gear

27610211

Crankshaft Timing Pin

Puller (Three Leg)

A2

Illustration 267

g01261155

Typical example

1. If necessary, install studs (2).

2. Align electric starting motor (1) to studs (2). Install
the electric starting motor.
3. Install nuts (3). Different types of starting motor
have different sized nuts.
Tighten M10 nuts to a torque of 44 11 Nm
(32 8 lb ft).
Tighten M12 nuts to a torque of 78 19.5 Nm
(57 14 lb ft).
4. Connect the harness assemblies to the electric
starting motor and the solenoid.
5. If necessary, install the hose for the crankcase
breather. Refer to Disassembly and Assembly,
Crankcase Breather - Install.
6. Connect the battery.

Part Name

Qty

Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Put identification marks on all hoses, on all
hose assemblies and on all tube assemblies for
installation purposes. Plug all hose assemblies and
tube assemblies. This helps to prevent fluid loss and
this helps to keep contaminants from entering the
system.

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
1. Release the pressure from the air system.

KENR6247

129
Disassembly and Assembly Section

2. 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 for the correct
draining procedure.
3. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
4. If the engine is equipped with a hydraulic pump
on the rear of the air compressor, remove the
hydraulic pump.
5. 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.
Note: The air compressor must be timed with the
engine in order to minimize engine vibration.

Illustration 269

g01250794

Typical example

7. Disconnect coolant hoses (1) and (2) from air

compressor (4).
8. Disconnect the air lines from ports (3) and (5).
Illustration 268

g01272266

Typical example

6. Install Tooling (B) through hole (X) in the front

housing. Use Tooling (B) in order to lock the
crankshaft.

9. Remove tube assembly (7) from air compressor

(4) and from the cylinder block.
10. Remove bolts (8) and (10) from support bracket
(9) and remove the support bracket.

130
Disassembly and Assembly Section

Illustration 270

KENR6247

g01250816

g01250889

Illustration 271

Typical example

Typical example

11. Support air compressor (4). Remove nuts (13)

and remove the air compressor from front housing
(6).

12. Remove O-ring seal (18) from air compressor (4).

13. If necessary, remove bolts (15) and remove plate
(14). Remove O-ring seal (11) from plate (14).
Refer to Illustration 270.
14. If necessary, remove nut (17) and remove
the spring washer. Use Tooling (C) in order to
remove gear (16) from the crankshaft of the air
compressor.

Installation Procedure
Table 76

Required Tools
Tool

Part
Number

27610211

Crankshaft Timing Pin

21826051

POWERPART
High Strength Retainer

21820221

POWERPART
Rubber Grease

Part Name

Qty

KENR6247

131
Disassembly and Assembly Section

c. Apply Tooling (D) to the threads of the shaft.

Install nut (17) to the shaft of air compressor
(4). Tighten the nut to a torque of 120 Nm
(89 lb ft).

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

2. Install the O-ring seal to air compressor (4). Use

Tooling (E) in order to lubricate the O-ring seal.
3. 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.
Note: The air compressor must be timed with the
engine in order to minimize engine vibration.

Dispose of all fluids according to local regulations and

mandates.

Illustration 273

g01272266

Typical example

4. Ensure that Tooling (B) is installed in hole (X) in

the front housing. Use Tooling (B) in order to lock
the crankshaft in the correct position.

Illustration 272

g01250889

Typical example

1. If necessary, follow Steps 1.a through 1.b in order

to install the gear to the air compressor.
a. Ensure that the shaft of air compressor (4) is
clean and dry. Ensure that gear (16) is clean
and free from damage.
b. Install gear (16) and a new spring washer to
the shaft of the air compressor.

Illustration 274
Typical air compressor with a SAE drive

g01250968

132
Disassembly and Assembly Section

KENR6247

Note: Ensure that timing mark (X) is aligned with

the timing mark A4. Refer to Illustration 274 for air
compressors with a SAE drive. Refer to Illustration
275 for air compressors with a DIN drive.
7. Install nuts (13). Tighten the nuts to a torque of
78 Nm (58 lb ft).
8. If necessary, follow Steps 8.a through 8.c in order
to install cover (14).
a. Install a new O-ring seal (11) to cover (14). Use
Tooling (E) in order to lubricate the O-ring seal.
Illustration 275

g01251223

Typical air compressor with a DIN drive

5. Rotate the crankshaft of the air compressor until

the timing mark (X) is aligned with the timing mark
A4 on the rear face of air compressor (4). Refer
to Illustration 274 for air compressors with a SAE
drive. Refer to Illustration 275 for air compressors
with a DIN drive.

b. Install cover (14) to air compressor (4).

c. Install bolts (15). Tighten the bolts to a torque
of 13 Nm (9.5 lb ft).

Illustration 277

g01250794

Typical example

9. Position support bracket (9) onto air compressor

(4). Install bolts (8) finger tight.
Illustration 276

g01250816

Typical example

6. Align the air compressor (4) with studs (12).

Install the air compressor to the front housing.
If necessary, rotate the crankshaft of the air
compressor in a clockwise direction in order to
align the gears.

10. Install bolts (10) finger tight.

11. Tighten the bolts (8) to a torque of 22 Nm
(16 lb ft). Tighten the bolts (10) to a torque 22 Nm
(16 lb ft).
Note: Ensure that the air compressor is not stressed
as the bolts are tightened.

KENR6247

133
Disassembly and Assembly Section

12. Install tube assembly (7) to air compressor (4)

and to the cylinder block. Tighten the nuts to a
torque of 9 Nm (80 lb in).
13. Remove Tooling (B) from hole (X) in the front
housing.
14. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
15. If the engine is equipped with a hydraulic pump
on the rear of the air compressor, install the
hydraulic pump.
16. Connect the air lines to ports (3) and (5) in the
air compressor.

Illustration 278

g01254510

Typical example

17. Connect coolant hoses (1) and (2) to air

compressor (4).

1. Remove tube assembly (4) from vacuum pump

(1) and from the cylinder block.

18. Fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance
Manual.
i02628914

2. Disconnect the vacuum line from connector (3) on

the vacuum pump.
3. Remove bolts (2). Remove vacuum pump (1) from
the front housing.

Vacuum Pump - Remove and

Install

4. Remove the joint.

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Installation Procedure

Contaminants may cause rapid wear and shortened

component life.
Note: Put identification marks on all hoses, on all
hose assemblies and on all tube assemblies for
installation purposes. Plug all hose assemblies and
tube assemblies. This helps to prevent fluid loss and
this helps to keep contaminants from entering the
system.

Illustration 279

g01254510

Typical example

1. Ensure that the vacuum pump is clean and free

from damage. If necessary, replace the vacuum
pump.
2. Clean the mating surfaces on the front housing.
3. Install a new joint to vacuum pump (1).

134
Disassembly and Assembly Section

4. Install vacuum pump (1) to the front housing. If

necessary, rotate the shaft of the vacuum pump in
order to align the gears.
5. Install bolts (2).
Tighten M8 bolts to a torque of 22 Nm (16 lb ft).
Tighten M10 bolts to a torque of 44 Nm (32 lb ft).
6. Connect the vacuum line to connector (3).
7. Install tube assembly (4) to vacuum pump (1) and
to the cylinder block. Tighten the nuts on the tube
assembly to a torque of 9 Nm (80 lb in).

KENR6247

KENR6247

135
Index Section

Index
A
Accessory Drive - Remove and Install................... 63
Installation Procedure ........................................ 64
Removal Procedure ........................................... 63
Air Compressor - Remove and Install.................. 128
Installation Procedure ...................................... 130
Removal Procedure ......................................... 128
Alternator - Install (Engines With an Automatic Belt
Tensioner) .......................................................... 126
Installation Procedure ...................................... 126
Alternator - Install (Engines Without an Automatic
Belt Tensioner)................................................... 127
Installation Procedure ...................................... 127
Alternator - Remove (Engines With an Automatic Belt
Tensioner) .......................................................... 125
Removal Procedure ......................................... 125
Alternator - Remove (Engines Without an Automatic
Belt Tensioner)................................................... 125
Removal Procedure ......................................... 125
Alternator Belt - Remove and Install (Engines With
an Automatic Belt Tensioner)............................. 122
Installation Procedure ...................................... 122
Removal Procedure ......................................... 122
B
Balancer - Install.................................................... 95
Assembly Procedure.......................................... 95
Installation Procedure ........................................ 96
Balancer - Remove................................................ 93
Disassembly Procedure ..................................... 94
Removal Procedure ........................................... 93
Bearing Clearance - Check .................................. 118
Measurement Procedure .................................. 118
C
Camshaft - Remove and Install ............................. 82
Installation Procedure ........................................ 83
Removal Procedure ........................................... 82
Camshaft Bearings - Remove and Install .............. 86
Installation Procedure ........................................ 87
Removal Procedure ........................................... 86
Camshaft Gear - Remove and Install .................... 84
Installation Procedure ........................................ 85
Removal Procedure ........................................... 84
Connecting Rod Bearings - Install (Connecting rods
in position) ......................................................... 106
Installation Procedure ...................................... 106
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................. 105
Removal Procedure ......................................... 105

Crankcase Breather - Remove and Install (Naturally

Aspirated Engines) .............................................. 69
Assembly Procedure.......................................... 70
Disassembly Procedure ..................................... 70
Installation Procedure ........................................ 70
Removal Procedure ........................................... 69
Crankcase Breather - Remove and Install
(Turbocharged Engines with Filtered Breather) ... 67
Assembly Procedure.......................................... 68
Disassembly Procedure ..................................... 67
Installation Procedure ........................................ 68
Removal Procedure ........................................... 67
Crankcase Breather - Remove and Install
(Turbocharged Engines with Unfiltered
Breather).............................................................. 65
Assembly Procedure.......................................... 66
Disassembly Procedure ..................................... 65
Installation Procedure ........................................ 66
Removal Procedure ........................................... 65
Crankshaft - Install................................................ 114
Installation Procedure ....................................... 114
Crankshaft - Remove............................................ 112
Removal Procedure .......................................... 112
Crankshaft Front Seal - Remove and Install.......... 46
Installation Procedure ........................................ 46
Removal Procedure ........................................... 46
Crankshaft Gear - Remove and Install ................. 117
Installation Procedure ....................................... 118
Removal Procedure .......................................... 117
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position)...................................... 108
Installation Procedure ...................................... 109
Removal Procedure ......................................... 108
Crankshaft Pulley - Remove and Install (Engines
With an Automatic Belt Tensioner)....................... 44
Installation Procedure ........................................ 44
Removal Procedure ........................................... 44
Crankshaft Pulley - Remove and Install (Engines
Without an Automatic Belt Tensioner).................. 45
Installation Procedure ........................................ 45
Removal Procedure ........................................... 45
Crankshaft Rear Seal - Install................................ 41
Installation Procedure ........................................ 41
Crankshaft Rear Seal - Remove............................ 40
Removal Procedure ........................................... 40
Crankshaft Wear Sleeve (Front) - Remove and
Install ................................................................... 47
Installation Procedure ........................................ 47
Removal Procedure ........................................... 47
Cylinder Head - Install ........................................... 78
Installation Procedure ........................................ 78
Cylinder Head - Remove ....................................... 76
Removal Procedure ........................................... 76
D
Disassembly and Assembly Section........................ 4

136
Index Section

E
Electric Starting Motor - Remove and Install ....... 127
Installation Procedure ...................................... 128
Removal Procedure ......................................... 127
Engine Oil Cooler - Install...................................... 28
Installation Procedure ........................................ 28
Engine Oil Cooler - Remove.................................. 27
Removal Procedure ........................................... 27
Engine Oil Filter Base - Remove and Install.......... 26
Installation Procedure ........................................ 26
Removal Procedure ........................................... 26
Engine Oil Pan - Remove and Install (Aluminum and
Pressed Steel Oil Pans)....................................... 87
Installation Procedure ........................................ 88
Removal Procedure ........................................... 87
Engine Oil Pan - Remove and Install (Cast Iron Oil
Pan) ..................................................................... 90
Installation Procedure ........................................ 92
Removal Procedure ........................................... 90
Engine Oil Pump - Remove and Install (Engines
Without a Balancer Unit)...................................... 32
Installation Procedure ........................................ 33
Removal Procedure ........................................... 32
Engine Oil Relief Valve - Remove and Install (Engines
with a Balancer Unit)............................................ 30
Installation Procedure ........................................ 31
Removal Procedure ........................................... 30
Engine Oil Relief Valve - Remove and Install (Engines
Without a Balancer Unit)...................................... 29
Installation Procedure ........................................ 30
Removal Procedure ........................................... 29
Exhaust Elbow - Remove and Install..................... 20
Installation Procedure ........................................ 20
Removal Procedure ........................................... 20
Exhaust Manifold - Remove and Install ................. 18
Installation Procedure ........................................ 19
Removal Procedure ........................................... 18

KENR6247

Fuel Injection Pump - Install .................................... 9

Installation Procedure .......................................... 9
Fuel Injection Pump - Remove ................................ 8
Removal Procedure ............................................. 8
Fuel Injection Pump Gear - Install ......................... 13
Installation Procedure ........................................ 13
Fuel Injection Pump Gear - Remove ...................... 11
Removal Procedure ............................................ 11
Fuel Injector - Install .............................................. 15
Installation Procedure ........................................ 15
Fuel Injector - Remove .......................................... 14
Removal Procedure ........................................... 14
Fuel Injector Cover - Remove and Install ................ 7
Installation Procedure .......................................... 7
Removal Procedure ............................................. 7
Fuel Priming Pump and Fuel Filter Base - Remove
and Install .............................................................. 4
Installation Procedure .......................................... 4
Removal Procedure ............................................. 4
G
Gear Group (Front) - Remove and Install.............. 50
Installation Procedure ........................................ 52
Removal Procedure ........................................... 50
Glow Plugs - Remove and Install ......................... 119
Installation Procedure ...................................... 120
Removal Procedure .......................................... 119
H
Housing (Front) - Install .........................................
Installation Procedure ........................................
Housing (Front) - Remove .....................................
Removal Procedure ...........................................

61
61
59
59

I
F
Fan - Remove and Install .................................... 123
Installation Procedure ...................................... 123
Removal Procedure ......................................... 123
Fan Drive - Remove and Install ........................... 124
Installation Procedure ...................................... 124
Removal Procedure ......................................... 124
Flywheel - Install.................................................... 39
Installation Procedure ........................................ 39
Flywheel - Remove................................................ 38
Removal Procedure ........................................... 38
Flywheel Housing - Remove and Install ................ 42
Installation Procedure ........................................ 43
Removal Procedure ........................................... 42
Front Cover - Remove and Install.......................... 49
Installation Procedure ........................................ 49
Removal Procedure ........................................... 49
Fuel Injection Lines - Remove and Install................ 5
Installation Procedure .......................................... 6
Removal Procedure ............................................. 5

Idler Gear - Install .................................................. 56

Installation Procedure (Heavy-Duty Idler Gear).. 58
Installation Procedure (Standard Idler Gear) ..... 56
Idler Gear - Remove .............................................. 53
Removal Procedure (Heavy-Duty Idler Gear) .... 55
Removal Procedure (Standard Idler Gear) ........ 53
Important Safety Information ................................... 2
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 21
Installation Procedure ........................................ 22
Removal Procedure ........................................... 21
Inlet and Exhaust Valves - Remove and Install ..... 23
Installation Procedure ........................................ 24
Removal Procedure ........................................... 23

KENR6247

137
Index Section

L
Lifter Group - Remove and Install.......................... 81
Installation Procedure ........................................ 81
Removal Procedure ........................................... 81
P
Piston Cooling Jets - Remove and Install.............. 97
Installation Procedure ........................................ 98
Removal Procedure ........................................... 97
Pistons and Connecting Rods - Assemble .......... 101
Assembly Procedure........................................ 101
Pistons and Connecting Rods - Disassemble ..... 100
Disassembly Procedure ................................... 100
Pistons and Connecting Rods - Install................. 103
Installation Procedure ...................................... 103
Pistons and Connecting Rods - Remove............... 99
Removal Procedure ........................................... 99
R
Rocker Shaft - Assemble.......................................
Assembly Procedure..........................................
Rocker Shaft - Disassemble ..................................
Disassembly Procedure .....................................
Rocker Shaft and Pushrod - Install........................
Installation Procedure ........................................
Rocker Shaft and Pushrod - Remove....................
Removal Procedure ...........................................

74
74
73
73
75
75
72
72

T
Table of Contents..................................................... 3
Turbocharger - Install ............................................ 17
Installation Procedure ........................................ 17
Turbocharger - Remove ........................................ 15
Removal Procedure ........................................... 15
V
V-Belts - Remove and Install (Engines Without an
Automatic Belt Tensioner )................................. 121
Installation Procedure ...................................... 121
Removal Procedure ......................................... 121
Vacuum Pump - Remove and Install ................... 133
Installation Procedure ...................................... 133
Removal Procedure ......................................... 133
Valve Mechanism Cover - Remove and Install...... 71
Installation Procedure ........................................ 72
Removal Procedure ........................................... 71
W
Water Pump - Install ..............................................
Installation Procedure ........................................
Water Pump - Remove ..........................................
Removal Procedure ...........................................

35
35
34
34

Water Temperature Regulator - Remove and

Install ................................................................... 36
Installation Procedure ........................................ 37
Removal Procedure ........................................... 36

138
Index Section

KENR6247