2020 Specialist

Tool Catalogue
Issue April 2020

THE HEART OF EVERY GREAT MACHINE

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  Contents 
Introduction Introduction

Perkins Service Tools

This revised catalogue forms part of Perkins specialist tooling process.
Perkins emphasises to its customers the need to use properly designed
and tested tools to carry out service and maintenance procedures in the
most correct, efficient and safe manner.

Perkins also recognises that some tools are available more readily than
the more specialised tools developed specifically for procedures on
Perkins engines.

For this reason, there is now a defined list of mandatory tools. Without
these special tools full and proper service of Perkins engines cannot be
performed.

It is Perkins intention that these mandatory tools are always available

from stock. Distributors are expected to have these in their workshops, for
engine types known to be in their territory. Periodical checks will occur to
maintain the levels to the required standards.

Tools outside of this list may not be in stock at all times but will be supplied
within lead-times quoted at the time of order.

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 Contents Contents

Contents
Engine Tool List
Introduction........................................................................................... 2
Contents ............................................................................................... 3
Service Matrix ...................................................................................... 7
3.152 Series ...................................................................................... 21
Cylinder Head ........................................................................................... 21
FIE............................................................................................................ 21
Timing ...................................................................................................... 21
Crankshaft ................................................................................................ 21
General..................................................................................................... 22
Electrical ................................................................................................... 22
4.236 Series....................................................................................... 23
Cylinder Head ........................................................................................... 23
FIE............................................................................................................ 23
Timing ...................................................................................................... 23
Crankshaft ................................................................................................ 23
Crankshaft continued ................................................................................ 24
General..................................................................................................... 24
Electrical ................................................................................................... 24
100 Series .......................................................................................... 25
Cylinder Block........................................................................................... 25
General..................................................................................................... 25
400 Series .......................................................................................... 26
Cylinder Head ........................................................................................... 26
FIE............................................................................................................ 26
Crankshaft ................................................................................................ 26
Crankshaft continued ................................................................................ 27
Cylinder Block........................................................................................... 27
General..................................................................................................... 27
General continued .................................................................................... 28
Electrical ................................................................................................... 28
500 Series .......................................................................................... 29
Cylinder Head ........................................................................................... 29
FIE............................................................................................................ 29
General..................................................................................................... 29
800 C – D Series ............................................................................... 30
Cylinder Head ........................................................................................... 30
FIE............................................................................................................ 30
Crankshaft ................................................................................................ 30
3

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 Contents General..................................................................................................... 31
850 Series .......................................................................................... 32
Cylinder Head ........................................................................................... 32
FIE............................................................................................................ 32
Crankshaft ................................................................................................ 33
General..................................................................................................... 33
Electrical ................................................................................................... 34
Aftertreatment ........................................................................................... 35
900 Series .......................................................................................... 36
Cylinder Head ........................................................................................... 36
FIE............................................................................................................ 36
Timing ...................................................................................................... 36
Crankshaft ................................................................................................ 37
General..................................................................................................... 37
904 Series .......................................................................................... 38
Cylinder Head ........................................................................................... 38
FIE............................................................................................................ 38
Timing ...................................................................................................... 39
Crankshaft ................................................................................................ 39
Electrical ................................................................................................... 40
Aftertreatment ........................................................................................... 40
General..................................................................................................... 41
1000 Series 4 - 6 ............................................................................... 42
Cylinder Head ........................................................................................... 42
FIE............................................................................................................ 42
Crankshaft ................................................................................................ 42
General..................................................................................................... 43
New 1000 Series ................................................................................ 44
Cylinder Head ........................................................................................... 44
FIE............................................................................................................ 44
Crankshaft ................................................................................................ 44
Electrical ................................................................................................... 45
General..................................................................................................... 45
1103 A B C D AA Series .................................................................. 46
Cylinder Head ........................................................................................... 46
FIE............................................................................................................ 46
Timing ...................................................................................................... 46
Crankshaft ................................................................................................ 47
General..................................................................................................... 47
Electrical ................................................................................................... 48
1104 / 1106 A B C D AA Series ...................................................... 49
Cylinder Head ........................................................................................... 49
FIE............................................................................................................ 49
Timing ...................................................................................................... 49
4

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 Contents Crankshaft ................................................................................................ 50
General..................................................................................................... 51
Electrical ................................................................................................... 52
1104 / 1106D Electronic ................................................................... 53
Cylinder Head ........................................................................................... 53
FIE............................................................................................................ 53
Timing ...................................................................................................... 54
Crankshaft ................................................................................................ 55
General..................................................................................................... 56
Electrical ................................................................................................... 57
1204 - 1206D Series......................................................................... 58
Cylinder Head ........................................................................................... 58
FIE............................................................................................................ 58
FIE continued ........................................................................................... 59
Timing ...................................................................................................... 59
Crankshaft ................................................................................................ 59
General..................................................................................................... 60
Electrical ................................................................................................... 61
Aftertreatment ........................................................................................... 62
1300 Series........................................................................................ 63
FIE............................................................................................................ 63
Timing ...................................................................................................... 63
Crankshaft ................................................................................................ 63
General..................................................................................................... 64
Electrical ................................................................................................... 64
1500 Series ........................................................................................ 65
Cylinder Head ........................................................................................... 65
FIE............................................................................................................ 65
Timing ...................................................................................................... 66
Crankshaft ................................................................................................ 67
Cylinder Block and Liner ........................................................................... 67
General..................................................................................................... 68
Electrical ................................................................................................... 69
1600 Series........................................................................................ 71
Cylinder Head ........................................................................................... 71
FIE............................................................................................................ 71
Crankshaft ................................................................................................ 72
General..................................................................................................... 72
Electrical ................................................................................................... 74
1706 Series........................................................................................ 75
Cylinder Block and Liner ........................................................................... 75
Cylinder Head ........................................................................................... 75
FIE............................................................................................................ 76
Crankshaft ................................................................................................ 76
5

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 Contents General..................................................................................................... 77
Electrical ................................................................................................... 78
Aftertreatment ........................................................................................... 78
2000 - 3000 Series ........................................................................... 79
Cylinder Head ........................................................................................... 79
FIE............................................................................................................ 79
Cylinder Block and Liner ........................................................................... 80
Cylinder Head ........................................................................................... 80
FIE............................................................................................................ 81
General..................................................................................................... 81
Electrical ................................................................................................... 83
2300 – 2500 and 2800 .......................................................................84
Cylinder Block and Liner ........................................................................... 84
Cylinder Head ........................................................................................... 85
FIE............................................................................................................ 86
Timing ...................................................................................................... 86
Crankshaft ................................................................................................ 87
General..................................................................................................... 87
Electrical ................................................................................................... 90
2400.................................................................................................... 91
Cylinder Block and Liner ........................................................................... 91
Cylinder Head ........................................................................................... 91
FIE............................................................................................................ 92
General..................................................................................................... 92
General continued .................................................................................... 93
Electrical ................................................................................................... 93
............................................................................................................ 94
Aftertreatment ........................................................................................... 94
4000 Series ....................................................................................... 95
Cylinder Head ........................................................................................... 95
FIE............................................................................................................ 96
Crankshaft ................................................................................................ 97
Electrical ................................................................................................... 98
General..................................................................................................... 98

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  Contents 
Service Matrix

Service Matrix

1103, 4 &
Part number Description

3.152

4.236

1106AA
Used

Used

Used
1000

1000
1103

1104

1106

1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904
Not

Not

Not
198217970 Spring
21825478 Main tool for valve guide removal and
installation
21825479 Adapter for use with 21825478
21825491 Piston ring compressor
21825496 Gauge, piston height and valve head
height (use with 21825617)
21825513 Adaptor, fuel pump timing gauge
21825515 Adaptor, fuel pump timing - Bosch (use
with 21825510)
21825540 Replacer, crankshaft rear oil seal
21825543 Cylinder liner remover / replacement tool
21825565 Remover, FIP and cam gear
21825571 Centraliser, timing case cover (3 cylinder)
21825574 Centraliser, timing cover - 6 cylinder
21825576 Crankshaft turning adaptor -- Superceded
by T400011
21825577 Replacer, crankshaft front oil seal - main
tool
21825578 Plate, crankshaft front oil seal replacement
(use with 21825577)
21825579 Sleeve, crankshaft front oil seal (use with
21825577)
21825580 Plate, crankshaft front oil seal
21825581 Crankshaft front oil seal replacer (use with
21825577)
21825607 Angle gauge
21825611 Wrench, fuel pump solenoid
21825615 Replacer tool for pistons
21825617 Dial gauge
21825620 Front oil seal protector (403C-11, 402D-05,
403D-11, 404D-15)
21825621 Front oil seal protector (403C- 15, 404C-
22,
403D-15, 404D-22)
21825623 Valve stem replacer
21825624 Installer, idler gear shaft (402C-05, 402D-05,
403D-07)
21825625 Installer, idler gear shaft (403C-11, 403D-11,
404C-15, 404D-15)
21825626 Installer, idler gear shaft
21825680 Fuel pump spill pipe
21825739 Valve spring compressor
21825741 Adaptor, valve spring compressor
21825765 Tool holder, injector sleeve face cutter /
reamer 3000 Series
21825767 Cutter, injector sleeve face 3000
21825768 Reamer, injector sleeve face 3000
21825771 Remover, injector sleeve 3000

7  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000
1103

1104

1106

1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904
Not

Not

Not
4&
21825776 Tube expander (pattern ‘C’ type)
21825849 Slide hammer 2000 / 3000
21825854 Adaptor kit, injector remover 3000 (use
with 21825849)
21825883 Ballizer, injector sleeve 3000
21825902 Lapping tool, cylinder liner (2000 and 3000)
21825914 Remover, injector 2000
21825920 Wrench, drive coupling 3000 only
21825922 Remover, injector and injector sleeve 2000
21825927 Adaptor, valve spring compressor (use with
21825739)
21825930 Fuel pump and camshaft gear remover bolt
21825933 Adaptor, valve spring compressor (use with
21825739)
21825934 Valve spring compressor adaptor (403D-
15, 404D-22, 900)
21825936 Centraliser, timing case (4 cyl)
21825938 Adjustable valve seat cutters
21825941 Adaptors, cylinder liner remover / replacer
(use with 21825543)
21825942 Adaptor, cylinder liner replacer (use with
21825543)
21825950 Socket, upper idler gear
21825951 Socket, lower idler gear
21825952 Plunger timing pin
21825953 Installer, front oil seal
21825956 Adaptor, cylinder liner remover
21825959 Kit, liner holding
21825960 Remover kit, injector sleeve
21825963 Installer, rear oil seal
21825965 Remover, crankshaft pulley
21826012 Installer, nozzle injector sleeve
2658A101 Dust cap - part of CH11147 oil sampling kit
– supercedes CH10821
27610022 Replacer, front oil seal
27610026 Adaptor, main tool to crankshaft nose
27610030 Valve seat and guide cutter / reamer
27610032 Timing pin - Bosch
27610033 Timing pin - Lucas, Stanadyne, Delphi
27610091 Electronic diesel injector (EDI) sleeve
removal tap
27610096 Locking pin for crankshaft
27610122 Fuel pump, drive gear retaining Torx
screwdriver
27610156 Power up harness
27610177 Detonation sensor removal tool

8  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000
1103

1104

1106

1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904
Not

Not

Not
4&
27610178 Cylinder head spark plug thread cleaning
kit
27610179 Flywheel support studs. Used on 4016
large nose
27610209 Tappet chamber oil plug removal tool
27610210 Tappet chamber oil plug fitting tool
27610211 Crankshaft locking pin
27610212 Camshaft gear locking pin
27610216 Timing case locating tool
27610217 FEOS fitting tool
27610218 Piston displacement tool
27610225 Balancer locking pin
27610226 Coolant thermostat valve assembly tool
27610227 Rocker assembly / removal - fitting tool
27610230 FEOS removal tool - twin / triple puller
27610233 Main bearing installation tool
27610234 Inlet and outlet valve guide adaptor
27610235 Adaptor for valve spring compressor 403D-
11, 404D-15, 800, 904J 1106D, 1200
27610248 Bosch EPVE fuel injection pump timing
adaptor
27610251 Compact communications Adaptor
(includes Adaptor, DL cable RJ45 and PC
Cable USB / AB
27610261 Valve stem seal installer
27610262 Valve guide driver
27610263 Valve guide collar
27610264 Inlet valve seat installer
27610266 Crankshaft rear end oil seal installer -
superceded by T403294
27610267 Crankshaft pulley socket
27610268 Crankshaft, front end oil seal installer
27610269 Idler gear shaft puller
27610272 Compression test gauge adaptor
27610274 Cylinder bore, ridge reamer
27610275 Crankshaft front bearing driver group
27610281 Lead to connect to 1300EDi engine, for use
with DIAG 1300 software
27610284 Installer
27610285 Extraction tool for Delphi connections –
superceded by T400080
27610286 Crankshaft locking pin with M18 X 1.5
thread
27610287 Crankshaft locking pin adapter
27610288 Fuel injector removal tool - pry bar
27610289 Barring tool gear - used with housing
27610291

9  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000
1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904
Not

Not

Not
4&
27610291 Engine barring tool housing - fits in starter
motor pocket of flywheel housing (used with
27610289)
27610292 Anchor plate 1104D and 1106D only
27610294 Injector pipe nut tool – superceded by
T402692
27610295 Valve spring compressor head
27610296 Torque wrench, electronic injector
connections. A 1/4" hex to 1/4" square
drive adaptor is required to enable a 1/4"
drive socket to be used)
27610298 Angled feeler gauges – superceded by
27610399
27610299 Torx E18 socket for front pulley fixings
27610301 Front oil seal removal tool
27610306 REOS alignment tool
27610307 Extended Torx driver, for injector clamp bolt
27610308 Surface reconditioning pad
27610309 Seal installer
27610311 Slide hammer- crankshaft oil seal removal
tool
27610312 Camshaft bearing pilot
27610313 Taper lock stud
27610314 Puller plate
27610315 Alignment bush
27610316 Backup plate
27610317 Bolt
27610318 Spacer plate
27610319 Bearing tool
27610321 Camshaft alignment tool – supeceded by
T400473
27610323 Injector leak off measure- ment kit 1104 /
1106D
27610325 Fuel pump pressure test "T" used with
27610326
27610326 Air in fuel sight tube
27610327 Installer, idler gear shaft - 403D-15 / 404D-
22 all
27610331 Dial gauge holder
27610332 Adaptor
27610336 Rear oil seal installation tool bolt –
supercedes 27610346
27610337 Hand held code reader (includes tool, cable
and manual)
27610345 Rear oil seal installation tool locator –
superceded by T433931
27610346 Rear oil seal installation tool bolt –
superceded by 27610336
27610347 Locator securing bolts (2 required)
27610352 Fuel pump timing tool for 1104 / 1106D

10  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904

Not

Not

Not
4&
27610355 Clamps (cylinder liner holding adaptor)
27610356 Crankshaft, front oil seal / wear sleeve
installer
27610358 Cylinder liner puller
27610359 Camshaft gear puller
27610361 Camshaft bushing service set
27610362 Injector sleeve removal
27610363 Injector sleeve installer
27610368 Valve guide installer tool
27610369 Valve guide removal tool
27610371 Piston ring compressor
27610374 Breakout harness
27610375 500 ohm resistor harness
27610376 3 banana plug harness
27610377 (EOT ECT EFT) temperature sensor
breakout harness
27610378 Relay breakout harness
27610379 Fuel pressure gauge
27610381 Fuel test fitting
27610384 Injection Control Pressure (ICP) adapter /
plug kit
27610386 Fuel / oil pressure test coupler
27610387 Injection control pressure (ICP) system test
adapter
27610389 Fuel pressure test kit
27610392 Fuel inlet restriction adapter
27610393 Pressure sensor universal harness
27610394 Pressure sensor universal harness
27610399 Angled feeler gauges – supercedes
27610298
27610401 Communication adapter 3 engines
equipped with an ECM
27610404 Power up harness
27610405 Rear seal installer
27610406 Barring over tool
27610411 High pressure rail adapter socket
28170079 Wedge Removal Tool
28170055 Receptacle – Supercedes T400932
28170085 Roll formed socket for 100W connector
OEM & Engine ECM connector
28170107 Harness
2817A001 Clip arrow head - harness clip –
supercedes 2900A012
2817A002 Clip - Fir tree harness clip – supercedes
2900A015
28710476 Hard washer

11  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904

Not

Not

Not
4&
2880A016 LCG2 communication adaptor
2900A011 Seal plug (fills unused pin locations)
2900A012 Clip arrow head - harness clip –
superceded by 2817A001
2900A015 Clip - Fir tree harness clip – superceded by
2817A002
2900A019 Gauge-Air Press
2900A036 Power up harness
2900A037 Bypass harness
2900A038 Power up harness Wiring Harness
2900A504 70 pin MIC breakout harness
29990021 Bolt
29990075 Capping kit
29990076 Deep socket IPR
3985063 Crimp Tool – superceded by T400243
484/45 Spark Plug Socket
484/49 Spark plug removal tool
680/219 USB dongle level 2
838/22 Timing calibration pick up probe - 4016TRS
CH10047 ‘O’ ring - part of CH11147 oil sampling kit
CH10133 ‘O’ ring - part of CH11147 oil sampling kit
CH10820 Adaptor - part of CH11147 oil sampling kit
CH10821 Dust cap - part of CH11147 oil sampling kit
– superceded by 2658A101
CH10822 Sampling valve - part of CH11147 oil
sampling kit
CH11147 Oil sampling tool kit, contains: adaptor
CH10820, sampling valve CH10822, dust
cap 2658A101, ‘O’ ring CH10133, O-ring
CH10047
CH11148 Engine turning tool - part of CH11150
CH11149 Setting gauge, fuel injector - part of
CH11150
CH11150 Essential maintenance tool kit, contains:
engine turning tool CH11148, injector
setting tool CH11149, oil sampling tool
CH11147, toolbox CH11305
CH11155 Crimp tool for harness repair kits
CH11169 Terminal insertion / extraction tool
CH12090 Piston ring compressor - 2800 Series 18
litre
CH12105 Camshaft guide
CH12571 Hard Washer
CVT0001 Valve guide driver
CVT0002 Valve guide collar
CVT0003 Valve spring compressor
CVT0004 Camshaft pilot

12  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904

Not

Not

Not
4&
CVT0005 Camshaft pilot
CVT0006 Receiving sleeve
CVT0007 Puller plate
CVT0008 Bearing pilot
CVT0009 Back up plate
CVT0010 Taperlock stud - cam bearing installation
CVT0011 Extension - short
CVT0012 Extension - long
CVT0013 Crank gear sleeve
CVT0014 Crank gear gauge
CVT0015 Timing pin adaptor
CVT0016 Piston ring compressor
CVT0017 Rear wear sleeve installer
CVT0018 Front wear sleeve installer
CVT0019 Adaptor cable 3-Pin connector
GE50000 Installer, cylinder liner
GE50001 Cylinder liner puller
GE50002 Cylinder liner projection tool
GE50003 Piston ring compressor
GE50005 Clamp bolt, cylinder liner (26 required)
GE50006 Washer
GE50007 Fibre washer
GE50008 Locator, crankshaft seal
GE50009 Bolt, crankshaft seal installer (use with
GE50008)
GE50010 Distorter, protection ring (use with
GE50008)
GE50011 Distorter tool (use with GE50008)
GE50012 Installer, front crankshaft seal (use with
GE500008)
GE50013 Installer, rear crankshaft seal (use with
GE50008)
GE50014 Nut (use with GE50008)
GE50015 Pilot, camshaft guide
GE50016 Alignment sleeve, camshaft guide
GE50017 Guide, camshaft
GE50018 Guide, camshaft
GE50019 Guide stud, camshaft gear
GE50020 Impact socket
GE50021 Remover / installer, injector sleeve
GE50022 Brush, large bore
GE50023 Brush, small tapered
GE50024 Brush, small bore
GE50025 Lifting hook, camshaft

13  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904

Not

Not

Not
4&
GE50026 Compressor, valve spring
GE50027 Installer, valve guide seal
GE50028 Vacuum pump
GE50030 Vacuum pump tube
GE50031 Pressurising pump, coolant system
GE50033 Air pressure gauge
GE50036 Service bypass harness - superceded by
U5MK0668
GE50037 70 pin (AMP) breakout harness (replaces
2900A025)
GE50038 Engine timing transducer
GE50039 Engine timing transducer adaptor
GE50040 Deutsch ‘DT’ timing probe cable
GE50041 3 pin DT breakout harness (supercedes
part numbers 2900A024 & CVT0019)
GE50042 Signal reading probe
GE50043 Remover / installer, valve guide
GE50044 Sleeve, valve guide
GE50045 Piston ring compressors
GE50046 Fluid sampling bottle, replaces part no.
GE50029
SE253 Crankshaft turning tool
SE671K 30 degree indicator socket tool
T400005 Spark plug bore, wire brush
T400006 Special 17mm socket
T400011 Crankshaft Turning Tool
T400015 Fuel pump locking pin, locks pump for
removal / refitting with engine at TDC
T400016 Bayonet front end oil seal fitting / removal
tool - all 1200 Series engines with steel
front covers
T400017 Timing case cover alignment tool for 6
cylinder 1200 Series products with steel
timing case cover
T400018 Centralising dolly for cast iron timing case
cover, 6 cylinder 1200 Series option
T400019 Exhaust manifold alignment pins - 2
required to support manifold on 6 cylinder
1200 Series product
T400020 Exhaust manifold alignment pins - 2
required to support manifold and joints on 6
cylinder 1200 Series product
T400021 Twin turbocharger alignment tool
T400023 Centralising dolly for cast iron timing case
cover, 4 cylinder 1200 Series option
T400025 Attenuator tool, RF sensor lead connector
T400026 Spark indicator for testing CEM spark plug -
Superceded by T400049

14  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000
1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904
Not

Not

Not
4&
T400027 Rocker arm spacer tool - 6 required on 6
litre products and 4 required on 4 litre
products
T400028 Turbocharger counter balance weight
T400031 Spark indicator grounding lead –
Superceded by T400049
T400049 Spark indicator grounding lead –
Supercedes T400031 & T400026
T400054 Timing case cover alignment tool for 4
cylinder 1200 Series product with steel
timing case cover. Supersedes T400022
T400080 Extraction tool for Delphi connections –
supercedes 27610285
T400084 Camshaft bush assembly punch (use with
T400085)
T400085 Handle, interchangeable driver (use with
T400084)
T400087 Centering ring for timing gear cover
T400089 Crankshaft rear seal installer
T400090 Crankshaft front seal installation and timing
cover centering
T400138 Common-rail fuel injection system test kit
T400152 Camshaft timing pin
T400153 Valve guide stop collar
T400154 Valve stem oil seal installation tool
T400155 Valve guide reamer
T400156 Engine turning tool for starter motor
aperture. Consists of two parts: 99307041 -
flywheel crank handle (use with 99307042)
T400157 Engine turning tool for starter motor
aperture. (use with T400156)

T400158 Valve spring compressor

T400159 Valve guide driver
T400195 DEF (Diesel Exhaust Fluid) quality
inspection
T400236 Kit for testing the DEF injector
T400240 Male probe connection (3mm) for 1206F
DEF system control module system test
T400241 Female probe connection (3mm) for 1206F
DEF system control module test
T400242 Male probe extra small connection (1.5mm
x 8mm) for 1206F DEF system control
module test
T400243 Male probe connection (0.6mm x 1mm) for
1206F DEF system control module test

T400450 854E Front End Oil Seal (FEOS)

installation and timing cover centering tool.
Used on seal part number T400452
T400473 Gear segment for setting backlash –
supercedes 27610321
T400657 Cap

15  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
New
100

400

500

700

800

850

900

904

Not

Not

Not
4&
T400920 Wire Removal tool
T400921 Capping Kit, DEF
T400922 Adaptor cable
T400923 Harness
T400924 Adaptor cable
T400925 Power cable
T400926 Harness
T400927 Connector pin
T400928 Pressure gauge
T400929 Adaptor cable
T400930 Harness assembly
T400931 ‘O’ ring seal, inside dia (mm) 6.07mm,
cross section dia (mm) 1.78mm
T400932 Receptacle - Superceded by 28170055
T401064 Rubber stopper
T401065 Sleeve installer
T401066 Large bore bush
T401068 Valve spring compressor
T401069 Guide collar
T401070 Guide collar
T401071 Seal driver (water pump seal )
T401072 Front seal installer
T401074 Camshaft bearing tool group
T401075 Piston ring compressor
T401076 Bracket assy (crankshaft removal and
installation)
T401077 Reamer
T401078 Tube brush
T401079 Seal protector
T401080 Seal installer
T401081 Fuel injector installation and removal tool
T401082 Plug tap
T401083 Guide sleeve
T401084 Bridge plate
T401085 Pulley stud
T401086 Full nut
T401087 Hard washer
T401088 Thrust bearing
T401089 Link bracket
T401167 Engine TDC positioning tool
T401198 DEF injector test group
T401199 DEF injector test group

16  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
904J

New
100

400

500

700

800

850

900

Not

Not

Not
4&
T401437 Fuel injector timing pin
T402028 Valve seat extractor
T402029 Valve seat driver
T402030 Water pump seal guide
T402031 Water pump seal installer
T402032 Piston ring expander
T402068 Cap
T402186 Kvaser communications adaptor connects
the engine controller / ECM to the laptop for
diagnostics. For use with harness extension
T402188
T402188 Harness extension for use with T402186
T402189 Dongle, plugs into PC / Laptop for user
access to software
T402191 DEF beaker assembly
T402192 DEF beaker assembly
T402225 Gear segment for setting backlash
T402260 Collar-Guide
T402387 Water pump seal installer
T402388 Dowel puller group used with T402389
T402389 Dowel extractor used with T402388
T402561 Crankshaft locking pin (1/4” NPT Thread)
T402686 Oil seal installation protector
T402692 Injector pipe nut tool – supercedes
27610294
T402828 Rectangular plate
T403294 Crankshaft rear end oil seal installer -
supercedes 27610266
T410437 Capping Kit Fuel
T412504 Capping kit
T416554 Protection kit
T418753 Oil pump puller
T418755 Oil pump puller
T430001 Driver-Valve
T430036 Front oil seal insertion kit
T430037 Rear oil seal insertion kit
T430038 Front oil seal insertion kit
T430039 Front oil seal insertion kit
T430188 Tool-Install
T430189 Driver-Seal
T430190 Eyebolt AS-LFT
T430192 Puller GP-CYL PK
T430193 Bridge GP
T430194 Eye As-Lifting

17  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
904J

New
100

400

500

700

800

850

900

Not

Not

Not
4&
T430195 Puller GP
T430196 Pump Alignment Tool assembly
T430543 Front oil seal insertion kit
T430640 Tool GP (Seal Guide)
T430935 PEC Governor Positioning Tool (vee)
T431398 PEC Governor Positioning Tool (in-line)
T431452 Tool group - Inlet Manifold Pressure Test
T431453 Indicator - Inlet Manifold Pressure Test
T431454 Multi Tool Group - Engine Crankcase
Pressure (Blowby) Test
T431455 Tool GP (Test Kit)
T431456 Tool As (Rail Plug Assembly)
T431457 Fuel Injection Line Assembly
T431458 Fuel Injection Line Assembly
T431459 Fuel Injection Line Assembly
T431460 Fuel Injection Line Assembly
T431461 Plug
T431462 Plug
T433585 Terminal Extraction Tool
T433931 Rear oil seal installation tool locator –
supercedes 27610345
T433997 Socket - removal / refit of relief valve (fuel
rail)
T434205 FEOS installation tool
T434206 REOS installation tool
T434207 FEOS removal tool
T434209 REOS removal tool
T434275 Adapter
T434369 A6:E10 ECM connector pin release tool
(CTX-J 50)
T434370 A6:E10 ECM connector pin release tool
(CTX-J 100)
T434371 A6:E10 ECM connector pin release tool
(CTX-J 280)
T434541 Fuel pump locking pin
T434542 Rocker shaft assembly aid (spacer)
T434543 Compression test gauge adaptor
T434544 Engine turning bracket
T434545 ECM breakout connector tees
T434546 PTO shaft cover removal tool
T434547 Front Pulley Engine Turning/Barring Tool
T433585 A6:E11 ECM connector pin release tool
T434607 Cam gear locking pin adaptor (use with
T402561)
T2653/265 Spark plug removal tool supercedes
T6253/265

18  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
904J

New
100

400

500

700

800

850

900

Not

Not

Not
4&
T6253/121 Pegged Socket
T6253/139 Piston ring compressing tool
T6253/140 Rear Oil Seal Insertion Kit – superceded by
T430037
T6253/141 Front Oil Seal Insertion Kit – superceded by
T430036 & T430038
T6253/142 Cam guide tool
T6253/144 Timing disc
T6253/146 Revised injector test adapter 12mm plunger
T6253/146B Spare set of ‘O’ rings for 12mm injectors
T6253/147 Injector compressor kit
T6253/149 1/2" Core plug inserter
T6253/152 Liner extractor
T6253/154 Cylinder head lifting tool
T6253/156 Injector bush coning tool (use with
21825589)
T6253/157 Support studs, flywheel and damper
T6253/159 Small end bush inserter and extractor
T6253/177 Fuel setting tool (later engines)
T6253/199 Cam bearing insert/removal (major
overhaul)
T6253/200 Liner clamp kit
T6253/202 Injector nozzle cleaning tools
T6253/208 Nozzle test master / injector tester
T6253/209 Crankshaft pulley extractor
T6253/209A Retaining plate
T6253/212 Piston crown handle
T6253/214 TV damper removal kit
T6253/236 Lifting eye
T6253/237 Cylinder head Lifting
T6253/238 Circlip pliers - internal
T6253/241 Heinzmann PG01 test unit
T6253/243 Valve Spring Compressor
T6253/256 Piston Ring Pliers
T6253/265 Spark plug removal tool superceded by
T2653/265
T6253/295 Piston removal tool for gas engines
T6253/307 Valve guide drift
T6253/350 Injector puller
T6253/353 Fuel injector setting tool - large spring
injectors
T6253/356 Revised injector test adaptor 14 mm
plunger
T6253/356B Spare set of ‘O’ rings for 14mm injectors
T85001/33 Gear spacing tool

19  Contents 
This document has been printed from SPI2. NOT FOR RESALE
  Contents 

Service Matrix Part number Description

3.152

4.236

1103,
Used

Used

Used
1000

1000

1103

1104

1106

1106
1200

1300

1500

1600

1706

2006

2206

2306

2400

2506

2806

3008

3012

4006

4008

4012

4016
904J

New
100

400

500

700

800

850

900

Not

Not

Not
4&
T85002/2 Injector bush inserting tool
T85002/3 Valve guide installation tool
T85002/4 Valve seat inserting guide
T85002/6 Injector bush (expanding tool) lower
T85002/7 Injector bush facing cutter
T85002/14B Injector bush depth gauge
T85002/58 Injector bush expanding tool (upper)
T85090/2 Valve Guide Installation Tool
T85117/3 Up rated valve seat inserting tool
T85316/1 Front oil insertion kit.
All 4008, 4016 from October 1997
T9142/8 Cup plug mandrel
T9142/21 Cup plug tool
U5MK0662 Wiring harness repair kit - SS to U5MK8194
U5MK0668 ECM power up harness, contains
2900A036, 2900A037 and 2900A038
U5MK1092 Spoon kit - Red and black (contains 7X-
1708 and 7X-1709) superceded by
GE50042
U5MK1110 Harness repair kit – Ampseal. Contains
pins, wires, connector seals and connector
bodies
U5MK1123 LCG1 communication adaptor
U5MK1124 Fuel system cleanliness kit (plugs / caps)
U5MK1130 ECG Electronic control governor
communication kit
U5MK8194 Harness repair kit – Deutsch. Contains
pins, wires, connector seals and connector
bodies. Also used with 1104C, 1106C,
1104D, 1106D, 2300 and 2800 Series
VP12712 Lift bracket, cylinder
Y06/00013 Level 2 dongle kit

20  Contents 
This document has been printed from SPI2. NOT FOR RESALE
 3.152 Series  Contents 
3.152 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)

FIE
Part Number Description Where used M or R Reference image
21825611 Wrench, fuel pump solenoid Engines fitted R
with
mechanical
rotary fuel
injection
pumps

Timing
Part Number Description Where used M or R Reference image
21825930 Fuel pump and camshaft gear 3.152 / 4.236 R
remover bolt

Crankshaft
Part Number Description Where used M or R Reference image
21825540 Replacer, crankshaft rear oil 3.152 / 4.236 R
seal

21825571 Centraliser, timing case cover 3.152 R

(3 cyl)

21825577 Replacer, crankshaft front oil 3.152 / 4.236 / R

seal - main tool 900 Series /
1000 Series /
1100 Series /
1200 Series

21 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
3.152 Series
Crankshaft continued
Part Number Description Where used M or R Reference image
21825578 Plate, crankshaft rear oil seal 3.152 / 4.236/ R
(use with 21825577) 900 Series /
1000 Series /
1100 Series /
1200 Series
21825579 Sleeve, crankshaft front oil seal 3.152 / 4.236/ R
(use with 21825577) 900 Series /
1000 Series /
1100 Series /
1200 Series
21825580 Plate, crankshaft front oil seal 3.152 / 4.236/ R
1000 Series /
1103 / 1104
21825581 Crankshaft front oil seal 3.152 / 4.236/ R
replacer (use with 21825577) 1000 Series /
1100 Series

General
Part Number Description Where used M or R Reference image
21825617 Dial gauge All products R

Electrical
Part Number Description Where used M or R Reference image
2880A016 LCG2 communication adaptor 3.152 / M
4.236 /
1000 Series

U5MK1123 LCG1 communication adaptor 3.152 / M

4.236 /
1000 Series

22 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
4.236 Series
4.236 Series
Cylinder Head
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)

21825607 Angle gauge All products R

27610030 Valve seat and guide cutter / 100 & 400 M

reamer Series

FIE
Part Number Description Where used M or R Reference image
21825611 Wrench, fuel pump solenoid Engines fitted R
with
mechanical
rotary fuel
injection pumps

Timing
Part Number Description Where used M or R Reference image
21825513 Adaptor, fuel pump timing 3.152 / 4.236 / M
gauge 1000 Series

21825930 Fuel pump and camshaft gear 3.152 / 4.236 R

remover bolt

Crankshaft
Part Number Description Where used M or R Reference image
21825540 Replacer, crankshaft rear oil seal 3.152 / 4.236 M

21825576 Crankshaft turning adaptor - 3.152 / 4.236 R

Superceded by T400011

21825577 Replacer, crankshaft front oil 3.152 / 4.236 / R

seal 900 Series /
- main tool 1000 Series /
1100 Series /
1200 Series
23 Note: M – Mandatory R - Recommended
 Contents 
cument has been printed from SPI2. NOT FOR R
 4.236 Series  Contents 

Crankshaft continued
21825578 Plate, crankshaft rear oil seal 3.152 / 4.236 / R
(use with 21825577) 900 Series /
1000 Series /
1100 Series /
1200 Series
21825579 Sleeve, crankshaft front oil seal 3.152 / 4.236 / R
(use with 21825577) 900 Series /
1000 Series /
1100 Series /
1200 Series
21825580 Plate, crankshaft front oil seal 3.152 / 4.236 R
/ 1000 Series /
1103 / 1104
21825581 Crankshaft front oil seal replacer 3.152 / 4.236 / R
(use with 21825577) 1000 Series /
1100 Series

General
Part Number Description Where used M or R Reference image
21825565 Remover, FIP and cam gear 3.152 / 4.236 R

21825617 Dial gauge All products R

21825936 Centraliser, timing case (4 4.236 M

cylinder)

Electrical
Part Number Description Where used M or R Reference image
2880A016 LCG2 communication adaptor 3.152 / 4.236 / M
1000 Series

U5MK1123 LCG1 communication adaptor 3.152 / 4.236 / M

1000 Series

24 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
100 Series 100 Series

Cylinder Block
Part Number Description Where used M or R Reference image
21825624 Installer, idler gear shaft 402C-05 / M
(402C-05, 402D-05, 403D-07) 402D-05 /
403D-07

21825625 Installer, idler gear shaft 403C-11 / M

(403C-11, 403D-11, 404C-15, 403D-11 /
404D-15) 404C-15 /
404D-15
21825626 Installer, idler gear shaft 404C-22 M

T418753 Oil pump puller 100 Series and M

400 Series
3 cylinder
T418755 Oil pump puller 100 Series and M
400 Series
3 cylinder

General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
21825617 Dial gauge All products R

25 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
400 Series 400 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825623 Valve stem replacer 400 Series R

21825739 Valve spring compressor 400 Series R

21825934 Valve spring compressor 403D-15 / R

adaptor (403D-15, 404D-22
404D-22)

27610235 Adaptor for valve spring 403D-11 / R

compressor 403D-11, 404D- 404D-15 /
15, 1106D 1106D

27610296 Torque wrench, crank breather 400 Series / R

1100 electronic
/ 1200 Series

FIE
Part Number Description Where used M or R Reference image
21825680 Fuel pump spill pipe 400 Series R

27610294 Injector pipe nut tool – 400, 1100 and R

Sepeceded by T402692 1200 Series

T402692 Injector pipe nut tool – 400, 1100 and R

supercedes 27610294 1200 Series

Crankshaft
Part Number Description Where used M or R Reference image
21825620 Front oil seal protector 403C-11 / 402D-05 R
(403C- 11, 402D-05, 403D- / 403D-11 / 404D-
11, 404D-15) 15
21825621 Front oil seal protector (403C- 403C-15 / 404C-22 R
15, 404C-22, 403D-15, 404D- / 403D-15 / 404D-
22) 22
27610275 Crankshaft front bearing 400, 800 and 1500 R
driver group Series

26 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 400 Series  Contents 

Crankshaft continued
27610311 Slide hammer - crankshaft 400, 800, 850, R
front oil seal removal 1000, 1500, 1600
Series, 2506, 4008
and 4016

Cylinder Block
Part Number Description Where used M or R Reference image
21825491 Piston ring compressor All products up to 9 R
litre capacity

21825625 Installer, idler gear shaft 403C-11 / 403D-11 M

(403C-11, 403D-11, 404C-15, / 404C-15 /
404D-15) 404D-15
21825626 Installer, idler gear shaft M

27610274 Cylinder bore, ridge reamer 400 Series R

27610327 Installer, idler gear shaft - 404C-22 / M

403D- 15 / 404D-22 all 404D-22

T418753 Oil pump puller 400 Series M

4 cylinder

T418755 Oil pump puller 100 Series and M

400 Series 3
cylinder

General
Part Number Description Where used M or R Reference image
198217970 Spring 400C R

21825496 Gauge, piston height and valve All products R

head height (use with
21825617)

27 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
400 Series
General continued
21825617 Dial gauge All products R

27610331 Dial gauge holder 400 Series M

27610332 Adaptor 400 Series R

Electrical
Part Number Description Where used M or R Reference image
T402186 Kvaser communications 400 Series gas R
adaptor connects the engine engines
controller / ECM to the laptop
for diagnostics. For use with
harness extension T402188
T402188 Harness extension for use with 400 Series gas R
T402186 engines

T402189 Dongle, plugs into PC / laptop 400 Series gas R

for user access to software engines

U5MK1130 ECG Electronic control Electronically M

governor communication kit controlled 400
Series

28 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 500 Series  Contents 
500 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825491 Piston ring compressor All products up R
to 9 litre
capacity

21825607 Angle gauge All products R

21825496 Gauge, piston height and valve All products R

head height (use with
21825617)

21825739 Valve spring compressor 500, 1100 and R

1600 Series

FIE
Part Number Description Where used M or R Reference image
21825611 Wrench, fuel pump solenoid On engines R
fitted with
mechanical
rotary fuel
injection pumps

General
Part Number Description Where used M or R Reference image
21825617 Dial gauge All products R

29 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 800 C – D Series  Contents 
800 C – D Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825938 Adjustable valve seat cutters 800 Series R

27610261 Valve stem seal installer 800 Series R

27610262 Valve guide driver 800 Series R

27610263 Valve guide collar 800 Series R

27610264 Inlet valve seat installer 800 Series R

FIE
Part Number Description Where used M or R Reference image
27610272 Compression test gauge 800 Series R
adaptor
27610294 Injector pipe nut tool – 400, 1100 and R
Sepeceded by T402692 1200 Series

T402692 Injector pipe nut tool – 400, 1100 and R

supercedes 27610294 1200 Series
27610296 Glow plug nut, torque wrench 800 Series R

Crankshaft
Part Number Description Where used M or R Reference image
27610266 Crankshaft rear end oil seal 800 Series R
installer - superceded by
T403294

T403294 Crankshaft rear end oil seal 800 Series R

installer - supercedes
27610266
27610267 Crankshaft pulley socket 800 Series R

27610268 Crankshaft, front end oil seal 800 Series R

installer

30 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
800 C – D Series
Crankshaft continued
27610311 Slide hammer - crankshaft 400, 800, 850, R
front oil seal removal 1000, 1500,
1600 Series,
2506, 4008 and
4016
27610345 Rear oil seal installation tool 800 Series R
locator – supeceded by
T433931
T433931 Rear oil seal installation tool 800 Series R
locator – supecedes 27610345
27610346 Rear oil seal installation tool 800 Series R
bolt Superceded by 27610336
27610347 Locator securing bolts (two 800 Series R
required)
28710476 Hard washer 800 Series R

General
Part Number Description Where used M or R Reference image
21825491 Piston ring compressor 800 Series R

21825496 Gauge, piston height and valve All products R

head height (use with
21825617)

21825617 Dial gauge All products R

27610269 Idler gear shaft puller 800 Series R

27610274 Cylinder bore, ridge reamer 800 Series R

27610275 Crankshaft front bearing driver 400 Series / R

group 800 Series /
1500 Series

31 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
850 Series 850 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825607 Angle gauge All products R

27610299 E18 Torx 1/2” drive 850 Series M

T400153 Valve guide stop collar 850 Series M

T400154 Valve stem oil seal installation 850 Series M

tool

T400155 Valve guide reamer 850 Series M

T400158 Valve spring compressor 850 Series R

T400159 Valve guide driver 850 Series M

FIE
Part Number Description Where used M or R Reference image
Fuel injection pump gear 850 Series R
retaining nut (19mm hex long
reach 1/2” drive)
T400138 Tool to check the diesel supply 850 Series R
circuit and the common rail
injection system

T400152 Camshaft timing pin 850 Series M

T401167 Engine TDC positioning tool 850 Series M

(Replaces part # T400086)

T412504 Capping kit 850 Series M

32 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 850 Series  Contents 

Crankshaft
Part Number Description Where used M or R Reference image
T400087 Centering ring for timing gear 850 Series M
cover, use with T400090 or
T400450. To be installed in the
crankcase breather aperture
T400089 Crankshaft Rear End Oil Seal 850 Series M
(REOS) installer

T400090 Crankshaft front seal installation 850 Series M

and timing cover centering
used to install seal part number
T412308
T400450 854E Front End Oil Seal 850 Series M
(FEOS) installation and timing
cover centering tool. Used on
seal part number T400452

General
Part Number Description Where used M or R Reference image
T400084 Camshaft bush assembly 850 Series M
punch. Mandatory, used with
T400084.

T400085 Handle, interchangeable driver. 850 Series M

Mandatory, used with T400084

T400156 Engine turning tool for starter 850 Series M

motor aperture. Use with part
number T400157
T400157 Engine turning tool for starter 850 Series M
motor aperture. Use with part
number T400156

21825491 Piston ring compressor 850 Series R

21825496 Gauge, piston height and valve All products R

head height (use with
21825617)

21825617 Dial gauge All products R

33 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
850 Series
General continued
27610274 Ridge reamer 850 Series R

27610285 Extraction tool for Delphi

connections - superceded by
T400080
T400080 Extraction tool for Delphi 1104D R
connections - supercedes Electronic / 850
27610285 Series

27610311 Slide hammer puller 400, 800, 850, R

1000, 1500,
1600 Series,
2506, 4008
and 4016

Electrical
Part Number Description Where used M or R Reference image
27610401 CA3 communication adapter kit 850 Series M
engines
equipped with
an ECM
2900A011 Seal plug (fills unused pin 850 Series R
locations) Industrial Open
Power Unit
(IOPU) / 1100
Series C and D
/ 1200 Series
Interim and
1200 Series
IOPU / 1500
Series

34 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 850 Series  Contents 

Aftertreatment
Part Number Description Where used M or R Reference image
T400195 DEF (Diesel Exhaust Fluid) 850 Series / R
quality inspection 1200 Series

T401198 DEF injector test group 850 Series, R

854F only

T402191 DEF beaker assembly 850 Series, R

854F only

35 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 900 Series  Contents 
900 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825478 Main tool for valve guide 900 Series R
removal and installation
21825607 Angle gauge All products R

FIE
Part Number Description Where used M or R Reference image
21825513 Adaptor, fuel pump timing 900 Series R
gauge

21825565 Remover, FIP (fuel injection 900 Series R

pump) and cam gear

21825611 Wrench, fuel pump solenoid Engines fitted R

with mechani-
cal rotary fuel
injection pumps

Timing
Part Number Description Where used M or R Reference image
27610096 Crankshaft locking pin, fits 900 Series R
through the backplate and
engages with a drilling in the
flywheel

36 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
900 Series
Crankshaft
Part Number Description Where used M or R Reference image
21825540 Replacer, crankshaft rear oil seal 900 Series R

21825576 Crankshaft turning adaptor - 900 Series R

Superceded by T400011

21825577 Replacer, crankshaft front oil 900 Series R

seal
- main tool

21825578 Plate, crankshaft front oil seal 900 Series R

(use with 21825577)

21825579 Sleeve, crankshaft rear oil seal 900 Series R

(use with 21825577)

General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)

21825571 Centraliser, timing case cover (3 900 Series R

cylinder)

21825617 Dial gauge All products R

37 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 904 Series  Contents 
904 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825607 Angle gauge All products R

21825739 Valve spring compressor 904J R

27610235 Adaptor for valve spring 904J R

compressor 403D-11, 404D-15,
1106D

27610295 Valve spring compressor head 904J R

T434542 Rocker shaft assembly aid 904J M

(spacer)

T434660 Tool to space rocker arms 904 Series R

during assembly C3.6

T434659 Tool to space rocker arms 904 Series R

during assembly C2.8

FIE
Part Number Description Where used M or R Reference image
T434541 Fuel pump locking pin, locks 904J Series M
pump for removal / refitting with
engine at TDC
T434543 Compression test gauge 904J M
adaptor

GE50028 Vacuum pump 904 Series R

GE50030 Vacuum pump tube 904 Series R

T412504 Capping kit 904 and 850 M

Series

T410437 Capping Kit Fuel 904J

38 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
904 Series
Timing
Part Number Description Where used M or R Reference image
T402561 Crankshaft locking pin. Used 904J 1706 M
with T434607 crankshaft 2400
locking pin adapter

T434607 Crankshaft locking pin adapter 904J M

used with T402561 crankshaft Series
locking pin

Crankshaft
Part Number Description Where used M or R Reference image
T434207 Crankshaft Front End Oil Seal 904J M
(FEOS) Remover

T434209 Crankshaft Rear End Oil Seal 904J M

(REOS) Remover

T434205 Crankshaft Front End Oil Seal 904J M

(FEOS) Installer

T434206 Crankshaft Rear End Oil Seal 904J M

(REOS) Installer

T434547 Front Pulley Engine M

Turning/Barring Tool
T434546 PTO shaft cover removal tool M

39 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
904 Series
Electrical
Where used M or R Reference image
T433585 Terminal Extraction Tool 904J Series M
E36

T434369 Terminal Extraction Tool (Molex CTX- 904J Series M

J 50)
E28

T434370 Terminal Extraction Tool (Molex CTX- 904J Series M

J 100)
E28

T434371 Terminal Extraction Tool (Molex CTX- 904J Series M

J 280)
E28

T434545 ECM breakout connector tees 904J Series M

T433585 A6:E11 ECM connector pin 904J Series M

release tool E36

Aftertreatment
Part Number Description Where used M or R Reference image
T400195 DEF (Diesel Exhaust Fluid) 850 Series / R
quality inspection 1200 Series

T402192 DEF beaker assembly 1204F R

T400921 Capping Kit, DEF 904J

40 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
904 Series
General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)

21825617 Dial gauge All products R

21825491 Piston ring compressor All products R

27610274 Ridge reamer 904J R

T400156 Engine turning handle (used 904J Series R

with T400157)

T400157 Engine turning pinion (used 904J Series R

with T400156)

T434544 Engine turning bracket 904J Series R

41 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1000 Series 4 - 6 1000 Series 4 - 6

Cylinder Head
Part Number Description Where used M or R Reference image
21825478 Main tool for valve guide 1000 Series R
removal and installation
21825479 Adapter used with 2185478 1000 Series / R
New 1000
Series
21825607 Angle gauge All products R

FIE
Part Number Description Where used M or R Reference image
21825513 Adaptor, fuel pump timing 3.152 / 4.236 / M
gauge 1000 Series

21825515 Adaptor, fuel pump timing - Engines with R

Bosch (use with 21825510) Bosch FIE
21825565 Remover, FIP and cam gear 3.152 / 4.236 / R
1000 Series

21825611 Wrench, fuel pump solenoid Engines fitted R

with mechanical
rotary fuel
injection pumps
21825930 Fuel pump and camshaft gear 3.152 / 4.236 / R
remover bolt 1000 Series

27610032 Timing pin - Bosch VP30 fuel New 1000 M

injection pump Series / 1104C
/ 1106C

Crankshaft
Part Number Description Where used M or R Reference image
21825540 Replacer, crankshaft rear oil 3.152 / 4.236 / R
seal 1000 Series

21825577 Replacer, crankshaft front oil 3.152 / 4.236 / R

seal - main tool 1000, 1100 and
1200 Series
21825578 Plate, crankshaft rear oil seal 3.152 / 4.236 / R
(use with 21825577) 1000, 1100 and
1200 Series
42 Note: M – Mandatory R - Recommended
 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1000 Series 4 - 6
Crankshaft continued
21825579 Sleeve, crankshaft rear oil seal 3.152 / 4.236 R
(use with 21825577) / 1000 Series /
1103 / 1104
21825580 Plate, crankshaft front oil seal 3.152 / 4.236 / R
1000 Series

21825581 Crankshaft front oil seal replacer 3.152 / 4.236 / R

(use with 21825577) 1000 and 1100
Series
T400011 Engine barring tool - fixes to 1000, New R
crankshaft pulley 1000, 1100 and
1200 Series

General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)

21825574 Centraliser, timing cover - 6 1006 R

cylinder

21825617 Dial gauge All products R

21825936 Centraliser, timing case (4 1004 R

cylinder)

21825543 Cylinder liner remover / 1000 Series R

replacement tool
21825941 Adaptors, cylinder liner 4.236 / 1000 R
remover / replacer (use with Series
21825543)
21825942 Adaptor, cylinder liner remover 4.236 / 1000 R
/ replacer (use with 21825543) Series

43 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
New 1000 Series New 1000 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825478 Main tool for valve guide New 1000 R
removal and installation Series
21825479 Adapter used with 2185478 1000 Series / R
New 1000
Series
21825607 Angle gauge All products R

27610091 Electronic diesel injector (EDI) New 1000 R

sleeve removal tap Series

FIE
Part Number Description Where used M or R Reference image
21825611 Wrench, fuel pump solenoid Engines fitted R
with mechanical
rotary fuel
injection pumps
27610032 Timing pin - Bosch VP30 fuel New 1000 M
injection pump Series / 1000
Series / 1104C
/ 1106C
27610033 Timing pin - Lucas, Stanadyne, New 1000 M
Delphi Series

27610122 Fuel pump, drive gear retaining New 1000 M

torx screw driver Series

Crankshaft
Part Number Description Where used M or R Reference image
21825577 Replacer, crankshaft front oil 3.152 / 4.236 / R
seal 900, 1000,
- main tool 1100 and 1200
Series
21825578 Plate, cranklshaft rear oil seal 3.152 / 4.236 / R
(use with 21825577) 900, 1000,
1100 and 1200
Series
21825579 Sleeve, crankshaft rear oil seal 3.152 / 4.236 / R
(use with 21825577) 1000 Series

44 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
New 1000 Series
Crankshaft continued
21825580 Plate, crankshaft front oil seal 3.152 / 4.236 / R
1000 Series /
1103 / 1104
21825581 Crankshaft front oil seal replacer 3.152 / 4.236 / R
(use with 21825577) 1000 and 1100
Series

27610233 Main bearing installation tool 1000 and 1100 R

Series

T400011 Engine barring tool - fixes to 1000, New R

crankshaft pulley 1000, 1100 and
1200 Series

Electrical
Part Number Description Where used M or R Reference image
2880A016 LCG2 communication adaptor 3.152 / 4.236 M
/1000 Series

U5MK1123 LCG1 communication adaptor 3.152 / 4.236 M

/1000 Series

General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
21825617 Dial gauge New 1000 R
Series

45 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1103 A B C D AA Series 1103 A B C D AA Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
21825607 Angle gauge All products R

27610226 Coolant thermostat valve 1103 / 1104C R

assembly tool

27610227 Rocker assembly / removal - 1100C M

fitting tool

FIE
Part Number Description Where used M or R Reference image
27610248 Bosch EPVE fuel injection 1104C M
pump timing adaptor

Timing
Part Number Description Where used M or R Reference image
27610211 Crankshaft locking pin 1103 / 1104C M

27610212 Camshaft gear locking pin 1103 / 1104C M

46 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1103 A B C D AA Series
Crankshaft
Part Number Description Where used M or R Reference image
21825577 Replacer, crankshaft front oil All products R
seal
- main tool

21825578 Plate, crankshaft rear oil seal All products R

(use with 21825577)

21825580 Plate, crankshaft front oil seal 1103C/D / R

1104C/D /
3.152 / 4.236 /
1000 Series
27610217 FEOS fitting tool 1104C/D R

27610233 Main bearing installation tool 1000 and 1100 R

Series

27610230 FEOS removal tool - twin / 1103C R

triple puller

General
Part Number Description Where used M or R Reference image
21825491 Piston ring compressor All products R

21825617 Dial gauge All products R

27610216 Timing case locating tool 1100 Series R

T400011 Engine barring tool - fixes to 1000, New R

crankshaft pulley 1000, 1100
and 1200
Series

47 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1103 A B C D AA Series
Electrical
Part Number Description Where used M or R Reference image
27610218 Piston displacement tool 1100 Series R
27610337 Hand held code reader 1100 Series R
(includes tool, cable & manual)

2880A016 LCG2 communication adaptor Engines fitted M

with Woodward
governors

2900A011 Seal plug (fills unused pin 850 Series R

locations) Industrial Open
Power Unit
(IOPU) / 1100
Series
C and D / 1200
Series Interim
and 1200 Series
IOPU / 1500
Series
2900A504 70 pin MIC breakout harness 1100 Series R
U5MK8194 Harness repair kit – Deutsch. 1104C / R
Contains pins, wires, connector 1106C /
seals and connector bodies.
1104D /
Also used with 1104C/1106C,
1104/11046D, 2300 / 2800 1106D / 2300
Series products and 2800
Series

48 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1104 / 1106 A B C D AA Series 1104 / 1106 A B C D AA Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825607 Angle gauge All products R

27610209 Tappet chamber oil plug 1100 Series R

removal tool
27610226 Coolant thermostat valve 1103 / 1104C R
assembly tool

27610227 Rocker assembly / removal - 1103 / 1104C R

fitting tool

27610210 Tappet chamber oil plug fitting 1100 Series R

tool
27610234 Inlet and outlet valve guide 1100 Series R
adaptor

FIE
Part Number Description Where used M or R Reference image
27610032 Timing pin - Bosch 1104C R
electronic

Timing
Part Number Description Where used M or R Reference image
27610211 Crankshaft locking pin 1103 / M
1104C/D
27610212 Camshaft gear locking pin 1100 and M
1200 Series

27610225 Balancer locking pin 1104C / M

1204E

49 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1104 / 1106 A B C D AA Series
Crankshaft
Part Number Description Where used M or R Reference image
21825577 Replacer, crankshaft front oil All products R
seal
- main tool

21825578 Plate, crankshaft rear oil seal All products R

(use with 21825577)

21825580 Plate, crankshaft front oil seal 1103 / 1104C / R

3.152 / 4.236 /
1000
Series
27610217 FEOS fitting tool 1103 / 1104C R

27610230 FEOS removal tool - twin / 1103 / 1104 / R

triple puller 1106C

27610233 Main bearing installation tool 1000 and 1100 R

Series

T400011 Engine barring tool - fixes to 1000, New R

crankshaft pulley 1000, 1100
and 1200
Series
27610306 REOS alignment tool 1106 R

50 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1104 / 1106 A B C D AA Series
General
Part Number Description Where used M or R Reference image
21825617 Dial gauge All products R

21825491 Piston ring compressor All products R

21825615 Replacer tool for pistons 1106 R

21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
27610216 Timing case locating tool 1103 / 1104 / R
1106C

27610218 Piston displacement tool 1100 Series R

27610274 Ridge reamer 1100 Series R

51 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1104 / 1106 A B C D AA Series
Electrical
Part Number Description Where used M or R Reference image
27610251 Compact communications All electronically R
adaptor (includes adaptor, DL (ECM)
cable RJ45 and PC Cable USB controlled
/ AB) products

27610337 Hand held code reader Engines R

(includes tool, cable and equipped with
manual) an ECM

27610401 CA3 communication adapter kit Engines R

equipped with
an ECM

2880A016 LCG2 communication adaptor 1000 and M

1100 Series

2900A011 Seal plug (fills unused pin 850 Series R

locations) Industrial Open
Power Unit
(IOPU) / 1100
Series C and D
/ 1200 Series
Interim and
1200 Series
IOPU / 1500
Series
CH11155 Crimp tool for harness repair 1104C/D / R
kits 1106C/D /
2300 and
2800 Series
U5MK0668 ECM power up harness, 1100 Series R
contains 2900A036, 2900A037
and 2900A038
U5MK1110 Harness repair kit – Ampseal. 1104C/D / R
Contains pins, wires, connector 1106C/D /
seals & connector bodies
2300 and
2800 Series

52 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1104 / 1106D Electronic  Contents 
1104 / 1106D Electronic

Cylinder Head
Part Number Description Where used M or R Reference image
21825478 Main tool for valve guide 1100 Series R
removal and installation
21825607 Angle gauge All products R

21825739 Valve spring compressor 1104D / R

1106D /
1200 Series
27610235 Adaptor for valve spring 1104D / R
compressor 403D-11, 404D- 1106D /
15, 1106D
1200 Series

27610295 Valve spring compressor head 1104D / R

1106D /
1200 Series

FIE
Part Number Description Where used M or R Reference image
27610288 Fuel injector removal tool - pry 1104D / M
bar 1106D /
1200 Series
4006D / 4008D
27610294 Injector pipe nut tool – 400, 1100 and R
Sepeceded by T402692 1200 Series

T402692 Injector pipe nut tool – 400, 1100 and R

supercedes 27610294 1200 Series
27610296 Torque wrench, electronic 400 Series / M
injector connections. (A 1/4" 1104D /
hex to 1/4" square drive 1106D
adaptor is required to enable a electronic /
1/4" drive socket to be used) 1200 Series
27610307 Extended Torx driver, for 1104D / R
injector clamp bolt 1106D
electronic /
1200 Series
27610323 Injector leak off measurement 1104D / M
kit 1106D
electronic

53 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1104 / 1106D Electronic
FIE continued
Part Number Description Where used M or R Reference image
27610325 Fuel pump pressure test "T" 1104D / R
used with 27610326 1106D
electronic

27610326 Air in fuel sight tube 1104D / R

1106D
electronic
27610352 Fuel pump timing tool 1104D / M
1106D
electronic
U5MK1124 Fuel system cleanliness kit 1100D all M
(plugs / caps)

Timing
Part Number Description Where used M or R Reference image
27610211 Crankshaft locking pin 1103 / M
1104C
27610212 Camshaft gear locking pin 1100 and M
1200 Series

27610225 Balancer locking pin 1104C/D / M

1204E

27610286 Crankshaft locking pin. Used 1104 / 1106D / M

with 27610287 crankshaft 1200 and 1500
locking pin adapter on 1106D Series / 2206 /
and 1200 Series engines 2506 / 2806
27610287 Crankshaft locking pin adapter 1106D / 1200 M
used with 27610286 Series
crankshaft locking pin

54 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1104 / 1106D Electronic  Contents 

Crankshaft
Part Number Description Where used M or R Reference image
21825577 Replacer, crankshaft front oil All products R
seal
- main tool
21825578 Plate, cranklshaft oil seal (use 1000, New R
with 21825577) 1000, 1100
and 1200
Series
27610217 FEOS fitting tool 1104C/D R

27610233 Main bearing installation tool 1000 and 1100 R

Series

27610284 Crankshaft FEOS installation 1000, New R

1000, 1100
and 1200
Series
27610292 Anchor plate 1106D R

27610301 Front oil seal removal tool 1106D R

T400011 Engine barring tool - fixes to 1000, New R

crankshaft pulley 1000, 1100
and 1200
Series

55 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1104 / 1106D Electronic  Contents 

General
Part Number Description Where used M or R Reference image
27610216 Timing case locating tool 1100C/D R

27610274 Ridge reamer 1100 Series R

27610289 Barring tool gear - used with All products R

housing 27610291

27610291 Engine barring tool housing - All products R

fits in starter motor pocket of
flywheel housing (used with
27610289)
27610298 Feeler gauges - supercecded 1106D R
by 27610399

27610299 Torx E18 socket for front pulley 1100 and M

fixings 1200 Series

27610298 Feeler gauges Supercedes 1106D

27610298
21825491 Piston ring compressor 1100 Series R

21825496 Gauge, piston height and valve All products R

head height (use with
21825617)

21825617 Dial gauge All products R

56 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1104 / 1106D Electronic  Contents 

Electrical
Part Number Description Where used M or R Reference image
27610251 Compact communications All ECM controlled R
adaptor (includes adaptor, DL electronic products
cable RJ45 & PC Cable USB
/ AB)
27610285 Extraction tool for Delphi
connections - superceded by
T400080
T400080 Extraction tool for Delphi 1104D R
connections - supercedes Electronic / 850
27610285 Series
27610401 CA3 communication adapter kit All ECM controlled M
electronic products

28170107 1100 stub adaptor for use with All engines equipped R
U5MK0668 ECM power up with an ECM
harness
2900A011 Seal plug (fills unused pin 850 Series In- R
locations) dustrial Open Power
Unit (IOPU) / 1100
Series C and D /
1200 Series Interim
and 1200 Series
IOPU / 1500
Series
CH11155 Crimp tool for harness repair 1100, 2300 R
kits and 2800 Series

U5MK1110 Harness repair kit – Ampseal. 1100, 2300 R

Contains pins, wires, connector and 2800 Series
seals & connector bodies
U5MK8194 Harness repair kit – Deutsch. 1100, 2300 R
Contains pins, wires, connector and 2800 Series
seals & connector bodies.

2817A001 Clip arrow head - harness clip – 1104 and 1106 R

supercedes 2900A012 series
2817A002 Clip - Fir tree harness clip – 1104 and 1106 R
supercedes 2900A015 series
28170085 Roll formed socket for 100W 1104 and 1106 R
connector OEM & Engine ECM series
connector

57 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1204 - 1206D Series  Contents 
1204 - 1206D Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825607 Angle gauge All products R

21825739 Valve spring compressor 1104 / 6D / R

1200 Series

27610235 Adaptor for valve spring 1104 / R

compressor 403D-11, 404D- 1106D /
15, 1106D
1200 Series
27610295 Valve spring compressor head 1104 / R
1106D /
1200 Series
T400027 Rocker arm spacer tool - 6 1204 / 6E R
required on 6 litre products and
4 required on 4 litre products
T400019 Exhaust manifold alignment 1200 Series R
pins - 2 required to support
manifold on 6 cylinder 1200
Series product
T400020 Exhaust manifold alignment 1200 Series R
pins - 2 required to support
manifold and joints on 6
cylinder 1200 Series product

FIE
Part Number Description Where used M or R Reference image
27610288 Fuel injector removal tool - pry 1100D M
bar electronic /
1200 Series
27610294 Injector pipe nut tool – 400, 1100 and R
Sepeceded by T402692 1200 Series

T402692 Injector pipe nut tool – 400, 1100 and R

supercedes 27610294 1200 Series
27610296 Torque wrench, electronic 400 Series / M
injector connections. (A 1/4" 1100D /
hex to 1/4" square drive 1200 Series
adaptor is required to enable a
1/4" drive socket to be used)
For access to fuel line 1200 Series M
connectors - Snapon

58 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1204 - 1206D Series  Contents 

FIE continued
T400015 Fuel pump locking pin, locks 1200 Series M
pump for removal / refitting
with engine at TDC
T433997 socket - removal / refit of relief 1204J Series M
valve (fuel rail)

Timing
Part Number Description Where used M or R Reference image
27610212 Camshaft gear locking pin 1100 and M
1200 Series

27610225 Balancer locking pin 1104C/D / M

1204E

27610286 Crankshaft locking pin. Used 1104 / M

with 27610287 crankshaft 1106D / 1200
locking pin adapter on 1106D
and 1500
and 1200 Series engines
Series / 2206 /
2506 / 2806
27610287 Crankshaft locking pin adapter 1106D / 1200 M
used with 27610286 crankshaft Series
locking pin

Crankshaft
Part Number Description Where used M or R Reference image
21825577 Replacer, crankshaft front oil All products R
seal
- main tool

21825578 Plate, cranklshaft oil seal (use All products R

with 21825577)

27610217 FEOS fitting tool 1106D short R

nose crank /
1206 Series
27610284 Installer - used with 21825577 1100 / R
1200 Series

T400011 Engine barring tool - fixes to 1000, New M

crankshaft pulley 1000, 1100
and 1200
Series
59 Note: M – Mandatory R - Recommended
 Contents 
cument has been printed from SPI2. NOT FOR R
 1204 - 1206D Series  Contents 

Crankshaft continued
T400016 Bayonet front end oil seal 1200 Series M
fitting
/ removal tool - all 1200 Series
engines with steel front covers
T400017 Timing case cover alignment 1206E / 7.1 M
tool for 6 cylinder 1200 Series
products with steel timing case
cover
T400018 Centralising dolly for cast iron 1206E / 7.1 R
timing case cover, 6 cylinder
1200 Series option

T400023 Centralising dolly for cast iron 1204E R

timing case cover, 4 cylinder
1200 Series option

T400054 Timing case cover alignment 1204E M

tool for 4 cylinder 1200 Series
product with steel timing case
cover. Supersedes T400022

General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
21825617 Dial gauge All products R

27610289 Barring tool gear - used with All products R

housing 27610291

27610291 Engine barring tool housing - All products R

fits in starter motor pocket of
flywheel housing (used with
27610289)
27610299 Torx E18 socket for front pulley 1106D / M
fixings 1200 Series

T400021 Twin turbocharger alignment 1206E R

tool

T400028 Turbocharger counter balance 1206E R

weight
60 Note: M – Mandatory R - Recommended
 Contents 
cument has been printed from SPI2. NOT FOR R
 1204 - 1206D Series  Contents 

Electrical
Part Number Description Where used M or R Reference image
27610251 Compact communications All electronically R
adaptor (includes adaptor, DL controlled
cable RJ45 and PC Cable USB products
/ AB)
27610401 CA3 communication adapter kit All ECM M
controlled
products

2900A011 Seal plug (fills unused pin 850 Series In- R

locations) dustrial Open
Power Unit
(IOPU) / 1100
Series C and D
/ 1200 Series
Interim and
1200 Series
IOPU / 1500
Series
CH11155 Crimp tool for harness repair 1104C/D / R
kits 1106 C/D /
2300 and
2800 Series
T400240 Male probe connection (3mm) 1200 Series R
for 1206F Def systen control
module system test
T400241 Female probe connection 1200 Series R
(3mm) for 1206F DEF system
control module test
T400242 Male probe extra small 1200 Series R
connection (1.5mm x 8mm) for
1206F DEF system control
module test
T400243 Male probe connection (0.6mm 1200 Series R
x 1mm) for 1206F DEF system
control module test
U5MK8194 Harness repair kit – Deutsch. 1104C/D / R
Contains pins, wires, connector 1106C/D /
seals and connector bodies.
2300 and
2800 Series

61 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1204 - 1206D Series  Contents 

Aftertreatment
Part Number Description Where used M or R Reference image
T400005 Spark plug bore, wire brush 1200 Series R
T400006 Socket - special 17.00mm 1200 Series R
T400025 RF sensor lead connector 1200 Series R

T400026 Spark indicator (Ground lead 1200 Series R

also required) - Superceded by
T400049

T400031 Spark indicator grounding lead 1200 Series R

- Superceded by T400049
T400049 Spark indicator and grounding
lead - Supercedes T400026 &
T400031
T400195 DEF quality inspection 850 and 1200 R
Series

T400236 Kit for testing the DEF injector. 1204F Tier 4 R

Kit contains beaker, test kit and later
(Diesel Exhaust Fluid (DEF), engines
dosing injector spray), DEF
refractometer, test lead, male
probe (3mm), female probe
(3mm), black and red test
plugs, hard case and foam
insert, wing nuts and screws
for attaching the DEF injector
to beaker
T401199 DEF injector test group 1204F Tier 4 R
and later
engines
T402192 DEF beaker assembly 1204F R

62 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1300 Series
1300 Series
FIE
Part Number Description Where used M or R Reference image
21825960 Remover kit, injector sleeve 1300 Series R

21826012 Installer, nozzle injector sleeve 1300 Series R

Timing
Part Number Description Where used M or R Reference image
21825950 Socket, upper idler gear 1300 Series R

21825951 Socket, lower idler gear 1300 Series R

21825952 Plunger timing pin 1300 Series R

Crankshaft
Part Number Description Where used M or R Reference image
21825953 Installer, front oil seal 1300 Series R

21825963 Installer, rear oil seal 1300 Series R

21825965 Remover, crankshaft pulley 1300 Series R

63 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1300 Series
General
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
21825617 Dial gauge All products R

21825956 Adaptor, cylinder liner remover 1300 Series R

21825959 Kit, liner holding 1300 Series R

Electrical
Part Number Description Where used M or R Reference image
27610156 Power up harness 1300 Series R
27610251 Compact communications All electronically M
adaptor (includes adaptor, DL (ECM)
cable RJ45 and PC Cable USB controlled
/ AB) products

27610281 Lead to connect to 1300EDi 1300 Series R

Engine, for use with DIAG
1300 software
27610401 CA3 communication adapter kit 1300 Series R

64 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1500 Series 1500 Series

Cylinder Head
Part Number Description Where used M or R Reference image
GE50043 Valve seat driver 1500 Series M

T401068 Valve spring compressor 1500 Series M

T401069 Guide collar 1500 Series M
For use with 27610262

T401070 Guide collar 1500 Series M

T401089 Link bracket 1500 Series R

27610262 Valve guide driver 1500 Series M

For use with T401069

FIE
Part Number Description Where used M or R Reference image
GE50023 Tapered brush 1500 Series R
GE50028 Vacuum pump 1500 Series R

GE50030 Vacuum pump tube 1500 Series R

GE50046 Fluid sampling bottle, replaces 2800, 2206, R

part number GE50029 4006D, 4008D

T401064 Rubber stopper 1500 Series M

T401065 Sleeve installer 1500 Series M
T401066 Large bore bush 1500 Series M

T401077 Reamer 1500 Series M

T401078 Tube brush 1500 Series M

T401079 Seal protector 1500 Series M

65 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1500 Series
FIE continued
Part Number Description Where used M or R Reference image
T401080 Seal installer 1500 Series M
T401081 Fuel injector installation and 1500 Series M
removal tool

T401082 Plug tap 1500 Series M

T401083 Guide sleeve 1500 Series M

T401084 Bridge plate 1500 Series M

T401085 Pulley stud 1500 Series M

T401086 Full nut 1500 Series M

T401087 Bolt 1500 Series M

T401088 Thrust bearing 1500 Series M

Timing
Part Number Description Where used M or R Reference image
27610275 Driver Gp 1500 Series M

27610286 Crankshaft locking pin. Used 1104 /1106D / M

with 27610287 crankshaft 1200 and 1500
locking pin adapter on 1106D Series / 2206
and 1200 Series /2506 / 2806

66 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1500 Series  Contents 

Crankshaft
Part Number Description Where used M or R Reference image
27610319 Bearing tool 1500 Series M

21825617 Dial gauge All products R

CVT0015 Timing pin adapter 1500 Series M

T401076 Bracket assembly (crankshaft 1500 Series R

removal and installation)

Cylinder Block and Liner

Part Number Description Where used M or R Reference image
27610336 Bolt 800 and 1500 M
Series

CH12571 Hard washer 1500 Series M

GE50000 Cylinder liner installer 1500 Series M

GE50001 Cylinder liner puller 1500 Series M

GE50002 Cylinder liner projection tool 1500 Series M

GE50006 Clamp washer 1500 Series M

67 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1500 Series
Cylinder Block and Liner continued
Part Number Description Where used M or R Reference image
GE50007 Fibre washer 1500 Series M

T401074 Camshaft bearing tool group 1500 Series M

T401075 Piston ring compressor 1500 Series M

General
Part Number Description Where used M or R Reference image
27610309 Seal installer 1500 Series M

27610311 Slide hammer puller 400, 800, 850, R

1600 Series
2506, 4008 and
4016

CH11148 Engine turning tool 1500 Series R

GE50031 Pressurising pump 1500 Series R

GE50033 Air pressure gauge 1500 Series R

T401071 Seal driver ( water pump seal ) 1500 Series M

T401072 Front seal installer 1500 Series M

68 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1500 Series
Electrical
Part Number Description Where used M or R Reference image
28170079 Wedge removal tool 1500 Series R
28170107 Harness 1500 Series R

2900A011 Seal plug (fills unused pin 850 Series In- R

locations) dustrial Open
Power Unit
(IOPU) / 1100
Series C and D /
1200 Series
Interim and
1200 Series
IOPU / 1500
Series
2900A038 Wiring harness 1500 Series R

CH11155 Crimp tool 1500 Series R

CVT0019 Adaptor cable 3-pin connector 1500 Series R

GE50037 70 pin (AMP) breakout harness 1500 Series R
(replaces 2900A025)

GE50038 Engine timing transducer 1500 Series R

GE50039 Engine timing transducer 1500 Series R

GE50040 Deutsch “DT” timing probe 1500 Series R
cable

T400920 Wire removal tool 1500 Series R

T400922 Adaptor cable 1500 Series R

T400923 Harness 1500 Series R

69 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1500 Series
Electrical continued
Part Number Description Where used M or R Reference image
T400924 Adaptor cable 1500 Series R

T400925 Power cable 1500 Series R

T400926 Harness 1500 Series R

T400927 Connector pin 1500 Series R

T400928 Pressure gauge 1500 Series R

T400929 Adaptor cable 1500 Series R

T400930 Harness assembly 1500 Series R

T400931 ‘O’ Ring seal, Inside dia 6.07 1500 Series R
mm, cross section dia
1.78 mm

28170055 Receptacle - Supercedes 1500 Series R

T400932

U5MK1110 Connector repair kit (AMPSEAL) 1500 Series R

U5MK8194 Connector repair kit (DEUTSCH 1500 Series R

DT)

70 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1600 Series  Contents 
1600 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825496 Gauge, piston height and valve All products R
head height (use with
21825617)
21825617 Dial gauge All products R

21825739 Valve spring compressor 1600 Series R

27610235 Valve spring compressor - 1600 Series R

adaptor

27610295 Valve spring compressor - 1600 Series R

head

27610368 Valve guide installer 1600 Series R

27610369 Valve guide removal tool 1600 Series R

FIE
Part Number Description Where used M or R Reference image
21825960 Slide hammer puller (injector 1600 Series R
sleeve)

27610307 T40 Torx socket 1600 Series R

27610362 Injector sleeve removal 1600 Series R

27610363 Injector sleeve installer 1600 Series R

27610411 High pressure rail adapter 1600 Series R

socket

29990076 Deep socket IPR 1600 Series R

71 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1600 Series  Contents 

Crankshaft
Part Number Description Where used M or R Reference image
27610311 Slide hammer puller (FEOS and 400, 800, 850, R
REOS removal) 1000, 1500,
1600 Series
2506, 4008
and 4016
27610356 Crankshaft, front oil seal / wear 1600 Series R
sleeve installer

27610405 Rear seal installer 1600 Series R

General
Part Number Description Where used M or R Reference image
21825607 Angle gauge 1600 Series R

21825950 Upper idler gear socket 3/4” 1600 Series R

drive (upper hub)

21825951 Lower idler gear socket 3/4” 1600 Series R

drive (lower hub)

27610274 Ridge reamer 1600 Series R

27610355 Clamp (cylinder liner holding 1600 Series R

adaptor)

27610358 Cylinder liner puller 1600 Series R

27610359 Camshaft gear puller 1600 Series R

72 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1600 Series  Contents 

General continued
Part Number Description Where used M or R Reference image
27610361 Camshaft bushing service set 1600 Series R

27610371 Piston ring compressor 1600 Series R

27610406 Barring over tool 1600 Series R

29990075 Capping kit 1600 Series R

GE50028 Vacuum pump 1600 Series R

GE50030 Vacuum pump tube 1600 Series R

GE50046 Fluid sampling bottle, replaces 1500, 1600, R

part number GE50029 2200, 2300,
2500 and 2800,
2206, 4006D,
4008D

73 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1600 Series  Contents 

Electrical
Part Number Description Where used M or R Reference image
27610374 Breakout harness 1600 Series R
27610375 500 ohm resistor harness 1600 Series R
27610376 3 banana plug harness 1600 Series R
27610377 (EOT ECT EFT) temperature 1600 Series R
sensor breakout harness
27610378 Relay breakout harness 1600 Series R
27610379 Fuel pressure gauge 1600 Series R
27610381 Fuel test fitting 1600 Series R
27610384 Injection Control Pressure (ICP) 1600 Series R
adapter / plug kit
27610386 Fuel / oil pressure test coupler 1600 Series R
27610387 Injection Control Pressure (ICP) 1600 Series R
system test adapter
27610389 Fuel pressure test kit 1600 Series R
27610392 Fuel inlet restriction adapter 1600 Series R
27610393 Pressure sensor universal 1600 Series R
harness
27610401 CA3 communication adapter kit Engines R
equipped with
an ECM

27610404 Power up harness 1600 Series R

27610394 Pressure sensor universal 1600 Series R

harness

74 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1706 Series 1706 Series

Cylinder Block and Liner

Part Number Description Where used M or R Reference image
GE50000 Installer, cylinder liner 1500, 1706,
2306, 2506,
2806 Series

GE50002 Cylinder liner projection tool 1500, 1706,

2306, 2506,
2806 Series

T401074 Camshaft bearing tool group 1500, 1706

Series

Cylinder Head
Part Number Description Where used M or R Reference image
27610262 Valve guide driver 700, 1500, R
1706 Series

T401069 Guide collar 1500 1706 M

For use with 27610262 Series

T431452 Tool group - Inlet Manifold R

Pressure Test
T431453 Indicator - Inlet Manifold R
Pressure Test
T430188 Tool-Install (Guide Collar) For 1706 Series R
use with 27610262
T430192 Puller GP-CYL PK 1706 Series R

75 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1706 Series
FIE
Part Number Description Where used M or R Reference image
27610288 Fuel injector removal tool - pry 1106, 1200, R
bar 1706, 2206
Series
T401064 Rubber stopper 1500, 1706 R
Series
T430196 Pump Alignment Tool 1706 R
assembly
T431455 Test Kit 1706 R
T431456 Rail Plug Assembly 1706 R
T431457 Fuel Injection Line Assembly 1706 R
T431458 Fuel Injection Line Assembly 1706 R
T431459 Fuel Injection Line Assembly 1706 R
T431460 Fuel Injection Line Assembly 1706 R
T431461 Plug 1706 R
T400657 Cap 1706 R
T431462 Plug 1706 R
T402068 Cap 1706 R

Crankshaft
Part Number Description Where used M or R Reference image
27610275 Crankshaft front bearing driver 400, 700, 904, R
group 1500, 1706
Series

27610311 Slide hammer- crankshaft front 400, 800, 850, R

oil seal removal 1000, 1500,
1600, 1706,
2506, 4008,
4016 Series
T401076 Bracket assembly (crankshaft 1500, 1706 R
removal and installation) Series

T431454 Multi Tool Group - Engine 1706 Series R

Crankcase Pressure (Blowby)
Test

76 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
  Contents 
1706 Series
General
Part Number Description Where used M or R Reference image
21825617 Dial gauge All Products R

27610319 Bearing tool 1500, 1706, R

4008, 4016
Series

CH11148 Engine turning tool 1500, 1706, R

2206, 2306,
2506, 2806
Series
CVT0015 Timing pin adaptor 1500, 1706, R
2206, 2306,
2506, 2806
Series
GE50031 Pressurising pump, coolant 1500, 1706, R
system 2306, 2506,
2806 Series
GE50033 Air pressure gauge 1500, 1706, R
2306, 2506,
2806 Series
T401072 Front seal installer 1500, 1706 R
Series

T430190 Eyebolt AS-LFT 1706 Series R

T430193 Bridge GP 1706 Series R
T430194 Eye As-Lifting 1706 Series R
T430189 Driver-Seal 1706 Series R
T430195 Puller GP 1706 Series R
T430640 Tool GP (Seal Guide) 1706 Series R

77 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 1706 Series  Contents 

Electrical
Part Number Description Where used M or R Reference image
CH11155 Crimp tool for harness repair 1103, 1104, R
kits 1106, 1500,
1706, 2306,
2506, 2806
Series
CVT0019 Adaptor cable 3-pin connector 1500, 1706, R
2306, 2506,
2806 Series
T400242 Male probe extra small 1200, 1706 R
connection (1.5mm x 8mm) for Series
1706 DEF system control
module test
T400243 Male probe connection (0.6mm 1200, 1706 R
x 1mm) for 1706 DEF system Series
control module test
T400920 Wire removal tool 1500, 1706 R
Series
U5MK1110 Harness repair kit – Ampseal. 1106, 1200, R
Contains pins, wires, connector 1300, 1500,
seals & connector bodies 1600, 1706,
2006, 2206,
2306, 2506,
2806, 3012,
4008, 4016
Series
U5MK8194 Harness repair kit – Deutsch. 1103, 1104, R
Contains pins, wires, connector 1106, 1300,
seals & connector bodies. 1706 Series

Aftertreatment
Part Number Description Where used M or R Reference image
T400195 DEF (Diesel Exhaust Fluid) 850, 900, 904, R
quality inspection 1200, 1706
Series

T400236 Kit for testing the DEF injector. 1200, 1706 R

Kit contains beaker, test kit Series
(Diesel Exhaust Fluid (DEF),
dosing injector spray), DEF
refractometer, test lead, male
probe (3mm), female probe
(3mm), black and red test
plugs, hard case and foam
insert, attachments for DEF
injector to beaker
78 Note: M – Mandatory R - Recommended
 Contents 
cument has been printed from SPI2. NOT FOR R
 2000 - 3000 Series  Contents 
2000 - 3000 Series

Cylinder Head
Part Number Description Where used M or R Reference image
21825741 Adaptor, valve spring 3000 Series R
compressor

FIE
Part Number Description Where used M or R Reference image
21825765 Tool holder, injector sleeve face 3000 Series R
cutter / reamer
21825767 Cutter, injector sleeve face 3000 Series R

21825768 Reamer, injector sleeve face 3000 Series R

21825771 Remover, injector sleeve 3000 Series R

21825776 Tube expander (pattern ‘C’ R

type)
21825854 Adaptor kit, injector remover 3000 Series R
(use with 21825849)

21825883 Ballizer, injector sleeve 3000 Series R

21825914 Remover, injector 2000 Series R

21825920 Wrench, drive coupling 3000 Series R
21825922 Remover, injector and injector 2000 Series R
sleeve
21825902 Lapping tool, cylinder liner 2000 and 3000
(2000 and 3000) series

79 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 2206  Contents 
2206

Cylinder Block and Liner

Part Number Description Where used M or R Reference image
29990021 Cylinder bolt clamp 2206 M
CH12571 Cylinder clamp hard washer 2206 M

CVT0016 Piston ring compressor 2206 M

CVT0004 Camshaft pilot 2206 M

CVT0005 Camshaft pilot 2206 M
GE50000 Installer, cylinder liner 2206 M

GE50001 Cylinder liner puller 2206 M

GE50002 Cylinder liner projection tool 2206 M

GE50006 Washer (26 required) 2206 M

GE50007 Fibre washer (26 required) 2206 M

T402032 Piston ring expander 2206D R

Cylinder Head
Part Number Description Where used M or R Reference image
21825607 Angle gauge All products M

27610288 Fuel injector removal tool - pry 1106D / R

bar 1200 Series /
2206

80 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 2206  Contents 

Cylinder Head continued

Part Number Description Where used M or R Reference image
27610296 Torque wrench, electronic 1106D / R
injector connections. (A 1/4" 1200 Series /
hex to 1/4" square drive
2206
adaptor is required to enable a
1/4" drive socket to be used)
27610309 Water temperature regulator - 2206 M
seal installer

CVT0001 Valve guide driver 2206 M

CVT0002 Valve guide collar 2206 M
CVT0003 Valve spring compressor 2206 M
T402028 Valve seat extractor 2206D R
T402029 Valve seat driver 2206D R
CVT0011 Extension - short 2206 R

FIE
Part Number Description Where used M or R Reference image
GE50021 Remover / installer, injector 2206 / 4006D M
sleeve 4008D

GE50022 Brush, large bore 2206 / 4006D M

4008D
GE50023 Brush, small tapered 2206 / 4006D M
4008D
GE50024 Brush, small bore 2206 / 4006D M
4008D

General
Part Number Description Where used M or R Reference image
21825617 Dial gauge All products M

27610286 Crankshaft locking pin. Used 1104 / M

with 27610287 crankshaft 1106D / 1200
locking pin adapter on 1106D
and 1500
and 1200 Series engines
Series / 2206 /
2506 / 2806

81 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 2206  Contents 

General continued
Part Number Description Where used M or R Reference image
27610319 Bearing tool 2206 M

CH11148 Engine turning tool 2206 R

CH11147 Oil sampling tool kit, contains: 2206 R

adaptor CH10820, sampling
valve CH10822, dust cap
2658A101, ‘O’ ring CH10133,
O-ring CH10047
CVT0006 Receiving sleeve 2206 M
CVT0007 Puller plate 2206 M
CVT0008 Bearing pilot 2206 M
CVT0009 Back up plate 2206 M
CVT0010 Taperlock stud - cam bearing 2206 M
installation
CVT0012 Extension - long 2206 M
CVT0013 Crank gear sleeve 2206 M
CVT0014 Crank gear gauge 2206 M
CVT0015 Timing pin adaptor 2206 M

CVT0017 Rear wear sleeve installer 2206 M

CVT0018 Front wear sleeve installer 2206 M
GE50028 Vacuum pump 2206 / 4006D M
4008D
GE50030 Vacuum pump tube 2206 / 4006D M
4008D

GE50046 Fluid sampling bottle, 1500, 1600, M

replaces part number 2200, 2300,
GE50029 2500 and
2800, 2206,
4006D, 4008D

KPR1572 Oil sample kit, comprising of: 4000 Series M

sampling adaptor 33871121,
sampling bottle CH11144, self
adhesive labels 21820176

82 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 2206  Contents 

General continued
Part Number Description Where used M or R Reference image
T402030 Water pump seal guide 2206D R

T402031 Water pump seal installer 2206D R

T416554 Protection kit 2206 M

Electrical
Part Number Description Where used M or R Reference image
27610251 Compact communications Engines M
adaptor (includes adaptor, DL equipped with
cable RJ45 and PC Cable an ECM
USB/AB)

27610401 CA3 communication adapter kit Engines M

equipped with
an ECM

CH11155 Crimp tool for harness repair 1100C/D / M

kits 2300, 2500,
2800 and
1200 Series
CH11169 Terminal insertion / extraction 2206 / 2300, R
tool 2500 and
2800 Series
GE50036 Service bypass harness – 2206 M
superceded by U5MK0668
GE50037 70 pin (AMP) breakout harness 2206 M
(replaces 2900A025)
GE50038 Engine timing transducer 2206 M
GE50039 Engine timing transducer 2206 M
adaptor
GE50040 Deutsch "DT" timing probe 2206 M
cable
GE50042 Signal reading probe 2206 M

83 Note: M – Mandatory R - Recommended

 Contents 
cument has been printed from SPI2. NOT FOR R
 2300 – 2500 and 2800  Contents 
2300 – 2500 and 2800

Cylinder Block and Liner

Part Number Description Where used M or R Reference image
CH12090 Piston ring compressor - 2800 2800-18 M
Series 18 litre

CH12105 Camshaft guide 2300, 2500 R

and 2800
Series up to ‘C’
variant
GE50000 Installer, cylinder liner 2300, 2500 R
and 2800
Series

GE50001 Cylinder liner puller 2300, 2500 R

and 2800
Series

GE50002 Cylinder liner projection tool 2300, 2500 R

and 2800
Series

GE50003 Piston ring compressor - 2800 2800 Series M

Series 16 litre

GE50005 Clamp bolt, cylinder liner (26 2300, 2500 R

required) and 2800
Series

GE50006 Washer (26 required) 2300, 2500 R

and 2800
Series

GE50007 Fibre washer (26 required) 2300, 2500 R

and 2800
Series

GE50045 Piston ring compressor 2300 and M

2500 Series

GE50015 Pilot, camshaft guide 2300, 2500 M

and 2800
Series
GE50016 Alignment sleeve, camshaft 2300, 2500 and R
guide 2800 Series

84 Note: M – Mandatory R - Recommended

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 2300 – 2500 and 2800  Contents 

Cylinder Block and Liner continued

Part Number Description Where used M or R Reference image
GE50017 Guide, camshaft 2300, 2500 M
and 2800 Series

GE50018 Guide, camshaft 2300, 2500 R

and 2800
Series
GE50019 Guide stud, camshaft gear 2300, 2500 R
and 2800
Series

Cylinder Head
Part Number Description Where used M or R Reference image
GE50020 Impact socket 2300, 2500 and M
2800 Series
GE50021 Remover / installer, injector 2300, 2500 and M
sleeve 2800 Series

GE50022 Brush, large bore 2300, 2500 and M

2800 Series
GE50023 Brush, small tapered 2300, 2500 and M
2800 Series
GE50024 Brush, small bore 2300, 2500 and M
2800 Series
GE50026 Compressor, valve spring 2300, 2500 and M
2800 Series
GE50027 Installer, valve guide seal 2300, 2500 and R
2800 Series

GE50043 Remover / installer, valve 2300, 2500 and R

guide 2800 Series

GE50044 Sleeve, valve guide 2300, 2500 and R

2800 Series

CVT0011 Extension - short 2206 R

85 Note: M – Mandatory R - Recommended

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FIE
Part Number Description Where used M or R Reference image
CH11149 Setting gauge, fuel injector - 2300, 2500 M
part of CH11150 and 2800
Series
GE50028 Vacuum pump 2300, 2500 M
and 2800
Series
GE50046 Fluid sampling bottle, 1500, 1600, M
replaces part number 2200, 2300,
GE50029 2500 and
2800, 2206,
4006D, 4008D
GE50030 Vacuum pump tube 2300, 2500 M
and 2800
Series

Timing
Part Number Description Where used M or R Reference image
27610286 Crankshaft locking pin. Used 1104 / M
with 27610287 crankshaft 1106D / 1200
locking pin adapter on 1106D
and 1500
and 1200 Series engines
Series / 2206 /
2506 / 2806
T400473 Gear segment tool for setting 2306 and 2506 R
backlash – supercedes
27610321
T402225 Gear segment tool for setting 2806 R
backlash

T402828 Rectangular plate. Used to 2506 and R

hold the gear segment in place 2806
and prevent the segment tool
from rotating

86 Note: M – Mandatory R - Recommended

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 2300 – 2500 and 2800  Contents 

Crankshaft
Part Number Description Where used M or R Reference image
GE50008 Locator, crankshaft seal 2300, 2500 M
and 2800
Series

GE50009 Bolt, crankshaft seal installer 2300, 2500 M

(use with GE50008) and 2800
Series

GE50010 Distorter, protection ring (use 2300, 2500 M

with GE50008) and 2800
Series

GE50011 Distorter tool (use with 2300, 2500 M

GE50008) and 2800
Series

GE50012 Installer, front crankshaft seal 2300, 2500 M

(use with GE50008) and 2800
Series

GE50013 Installer, rear crankshaft seal 2300, 2500 M

(use with GE50008) and 2800
Series
GE50014 Nut (use with GE50008) 2300, 2500 M
and 2800
Series

General
Part Number Description Where used M or R Reference image
27610313 Taper lock stud 2506 R
27610308 Surface reconditioning pad 2506, 4006D, R
4008D
27610309 Seal installer 2506 R

27610311 Slide hammer- crankshaft front 400, 800, 850, R

oil seal removal 1000, 1500,
1600 Series,
2506, 4008
and 4016

87 Note: M – Mandatory R - Recommended

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General continued
Part Number Description Where used M or R Reference image
27610312 Camshaft bearing pilot 2506 R

27610314 Puller plate 2506 R

27610315 Alignment bush 2506 R
27610316 Backup plate 2506 R
27610317 Bolt 2506 R
27610318 Spacer plate 2506 R
27610319 Bearing tool 2406, 2506 R

27610321 Camshaft alignment tool – 2506 R

superceded by T400473
CH11147 Oil sampling tool kit, contains: 2300, 2500 M
adaptor CH10820, sampling and 2800
valve CH10822, dust cap Series
2658A101, ‘O’ Ring CH10133,
O-Ring CH10047
CH11148 Engine turning tool 2300, 2400, M
2500
and 2800
Series
CH11150 Essential maintenance tool kit, 2300, 2500 R
contains: engine turning tool and 2800
CH11148, injector setting tool Series
CH11149, oil sampling tool
CH11147, toolbox CH11305
GE50025 Lifting hook, camshaft 2300, 2500 R
and 2800
Series

GE50031 Pressurising pump, coolant 2300 and R

system 2800 Series

GE50033 Air pressure gauge 2300 and R

2800 Series

T400473 Gear segment tool for setting 2306 and 2506 R

backlash – supercedes
27610321
T402387 Water pump seal installer 2806 C, D M
and F

88 Note: M – Mandatory R - Recommended

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 2300 – 2500 and 2800  Contents 

General continued
Part Number Description Where used M or R Reference image
T402388 Dowel puller group used with 2806 C and D R
T402389
T402389 Dowel extractor used with 2806 C and D R
T402388
T402686 Oil seal installation protector 2806 C, D M
and F
VP12712 Lift bracket, cylinder 2300, 2500 M
and 2800
Series

89 Note: M – Mandatory R - Recommended

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 2300 – 2500 and 2800  Contents 

Electrical
Part Number Description Where used M or R Reference image
27610251 Compact communications All electronically M
adaptor (includes adaptor, DL (ECM)
cable RJ45 and PC Cable USB controlled
/ AB) products

27610401 CA3 communication adapter kit Engines R

equipped with
an ECM

CH11155 Crimp tool for harness repair 2300, 2400, R

kits 2500
and 2800
Series
CH11169 Terminal insertion / extraction 2206 / 2300, R
tool 2500 and
2800 Series
GE50036 Service bypass harness – 2300, 2500 R
superceded by U5MK0668 and 2800
Series

GE50037 70 pin (AMP) breakout harness 2300, 2500 R

(replaces 2900A025) and 2800
Series
GE50038 Engine timing transducer 2300, 2500 M
and 2800
Series
GE50039 Engine timing transducer 2300, 2500 M
adaptor and 2800
Series
GE50040 Deutsch "DT" timing probe 2300, 2500 M
cable and 2800
Series
GE50041 3 pin DT breakout harness 2300, 2500 M
(replaces 2900A024) and 2800
supercedes to Part Number Series
CVT0019
GE50042 Signal reading probe 2300, 2500 M
and 2800
Series

90 Note: M – Mandatory R - Recommended

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  Contents 
2400 2400

Cylinder Block and Liner

Part Number Description Where used M or R Reference image
CVT0004 Camshaft pilot 2306,2400,
2506, 2806
Series
CVT0005 Camshaft pilot 2306,2400,
2506, 2806
Series
CVT0016 Piston ring compressor 2306,2400,
2506, 2806
Series
GE50000 Installer, cylinder liner 1500,
2306,2400,
2506, 2806
Series
GE50001 Cylinder liner puller 1500,
2306,2400,
2506, 2806
Series
GE50002 Cylinder liner projection tool 1500,
2306,2400,
2506, 2806
Series
T402032 Piston ring expander 2206, 2400
Series

Cylinder Head
Part Number Description Where used M or R Reference image
CVT0001 Valve guide driver 2306,2400, 2506,
2806 Series
CVT0002 Valve guide collar 2306,2400, 2506,
2806 Series
CVT0003 Valve spring compressor 2206, 2306,2400,
2506, 2806 Series
T402028 Valve seat extractor 2206, 2400 Series
T402029 Valve seat driver 2206, 2400 Series
T402260 Collar-Guide 2400 Series

91 Note: M – Mandatory R - Recommended

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 2400  Contents 

FIE
Part Number Description Where used M or R Reference image
GE50021 Remover / installer, injector 2206,
sleeve 2306,2400,
2506, 2806,
4006, 4008
Series
T434275 Adapter 2406J

General
Part Number Description Where used M or R Reference image
21825617 Dial gauge All products R

27610319 Bearing tool 2400, 2506 R

CH11148 Engine turning tool 2300, 2400, M

2500
and 2800
Series
CVT0006 Receiving sleeve 2206,
2306,2400,
2506, 2806
Series
CVT0007 Puller plate 2206,
2306,2400,
2506, 2806
Series
CVT0008 Bearing pilot 2206,
2306,2400,
2506, 2806
Series
CVT0009 Back up plate 2206,
2306,2400,
2506, 2806
Series
CVT0012 Extension - long 2206,
2306,2400,
2506, 2806
Series

92 Note: M – Mandatory R - Recommended

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 2400  Contents 

General continued
GE50031 Pressurising pump, coolant 1500, 2300, R
system 2400, 2500,
2800 Series
GE50033 Air pressure gauge 1500, 2300, R
2400, 2500,
2800 Series

2900A019 Gauge-Air Press 2406 series

T430001 Driver-Valve 2400 series

Electrical
Part Number Description Where used M or R Reference image
27610401 CA3 communication adapter kit 850, 1104, R
1106, 1200,
1600, 2206,
2306, 2400,
2506, 4006,
4012 Series
2900A038 Wiring Harness 1104,
1106,1500,
2400 Series

CH11155 Crimp tool for harness repair 1103, 1104, R

kits 1106, 1500,
2306, 2400,
2506, 2806
Series
T400242 Male probe extra small 1200, 2400
connection (1.5mm x 8mm) for Series
1206F DEF system control
module test
T400926 Harness 1500, 2400 R
Series

93 Note: M – Mandatory R - Recommended

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 2400  Contents 

Aftertreatment
Part Number Description Where used M or R Reference image
T400236 Kit for testing the DEF injector. 1200, 2400
Kit contains beaker, test kit Series
(Diesel Exhaust Fluid (DEF),
dosing injector spray), DEF
refractometer, test lead, male
probe (3mm), female probe
(3mm), black and red test
plugs, hard case and foam
insert, wing nuts and screws
for attaching the DEF injector
to beaker
T400195 DEF (Diesel Exhaust Fluid) 850, 1200, 2400 R
quality inspection Series

94 Note: M – Mandatory R - Recommended

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 4000 Series  Contents 
4000 Series

Cylinder Head
Part Number Description Where used M or R Reference image
T6253/156 Injector bush coning tool (use 4000 Series R
with 21825589)

T6253/307 Valve guide drift 4000 Series R

T85002/2 Injector bush inserting tool 4000 Series R

T85002/3 Valve guide installation tool 4000 Series R

T85002/4 Valve seat inserting tool 4000 Series R
T85002/6 Injector bush (expanding tool) 4000 Series R
lower
T85002/7 Injector bush facing cutter 4000 Series R
T85002/14B Injector bush depth gauge 4000 Series R

T85002/58 Injector bush expanding tool 4000 Series R

(upper)

T85117/3 Up rated valve seat inserting 4000 Series R

tool
T9142/21 Cup plug tool 4000 Series R
T2653/265 Spark plug removal tool 4000 Series R
supercedes T6253/265
T6253/154 Cylinder head lifting tool 4000 Series R

T6253/243 Valve Spring Compressor 4000 Series R

T6253/256 Piston Ring Pliers 4000 Series R

95 Note: M – Mandatory R - Recommended

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 4000 Series  Contents 

FIE
Part Number Description Where used M or R Reference image
27610178 Cylinder head spark plug 4000 Series R
thread cleaning kit

GE50021 Injector sleeve remover / 2206 / 4006D M

installer 4008D

GE50022 Brush, large bore 2206 / 4006D M

4008D
GE50023 Brush, small tapered 2206 / 4006D M
4008D
GE50024 Brush, small bore 2206 / 4006D M
4008D
T401437 Fuel injector timing pin 4000 Series M

T6253/146 Revised injector test adapter 4000 Series R

12mm plunger
T6253/146B Spare set of ‘O’ rings for 12mm 4000 Series M
injectors

T6253/147 Injector compressor kit (one 4000 Series M

required per cylinder)

T6253/177 Fuel setting tool (later engines) 4000 Series M

T6253/202 Injector nozzle cleaning tools 4000 Series R

T6253/208 Nozzle test master / injector 4000 Series R
tester
T6253/350 Injector puller 4000 Series R

T6253/353 Fuel injector setting tool large 4000 Series M

spring injectors

T6253/356 Revised injector test adaptor 4000 Series R

14.00mm plunger
T6253/356B Spare set of ‘O’ rings for 14mm 4000 Series R
injectors

96 Note: M – Mandatory R - Recommended

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 4000 Series  Contents 

Crankshaft
Part Number Description Where used M or R Reference image
27610179 Flywheel support studs Used 4000 Series R
on 4016 large nose
T6253/157 Support studs - flywheel and 4000 Series R
damper
T6253/209 Crankshaft pulley extractor 4000 Series M

T6253/209A Retaining plate 4000 Series R

T6253/214 TV Damper removal kit 4000 Series R

T85316/1 Front oil insertion kit All 4008 M
4016 up to
October 1997
T430036 Front oil seal insertion kit 4012 M

T430037 Rear oil seal insertion kit 4000 Series M

T430038 Front oil seal insertion kit 4006 M

T430039 Front oil seal insertion kit 4016 M

T430543 Front oil seal insertion kit 4008 M

T85090/2 Valve Guide Installation Tool 4008 and 4016

97 Note: M – Mandatory R - Recommended

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 4000 Series  Contents 

Electrical
Part Number Description Where used M or R Reference image
27610251 Compact communications All R
adaptor (includes adaptor, DL electronically
cable RJ45 and PC Cable USB (ECM)
/ AB) controlled
products
27610401 CA3 communication adapter kit 4000 Series R

680/219 USB dongle level 2 4000 Series M

838/22 Timing calibration pick up 4016-E61TRS M

probe
T6253/241 Heinzmann PG01 test unit 4000 Series M

Y06/00013 Level 2 dongle kit 4000 Series M

General
Part Number Description Where used M or R Reference image
484/49 Multi torch plug remover 4000 Series R

27610308 Surface reconditioning pad 2506, 4006D, R

4008D
27610311 Slide hammer - crankshaft oil 400, 800, 850, R
seal removal 1000, 1500,
1600 Series,
2506, 4008
and 4016
27610177 Detonation sensor removal tool 4016-E61TRS M
GE50028 Vacuum pump 2206 / 4006D M
4008D
GE50030 Vacuum pump tube 2206 / 4006D M
4008D

GE50046 Fluid sampling bottle, 1500, 1600, M

replaces part number 2200, 2300,
GE50029 2500 and
2800, 2206,
4006D, 4008D

98 Note: M – Mandatory R - Recommended

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 4000 Series  Contents 

General continued
SE253 Crankshaft turning tool 4000 Series R

SE671K 30 degree indicator socket tool 4000 Series M

T6253/139 Piston ring compressing tool 4000 Series R

T6253/142 Cam guide tool 4000 Series R

T6253/144 Timing disc 4000 Series R

T6253/149 1/2” core plug inserter 4000 Series R
T6253/152 Liner extractor 4000 Series M

T6253/159 Small end bush inserter and 4000 Series R

extractor

T6253/199 Cam bearing insert/removal 4000 Series R

(major overhaul)

T6253/200 Liner clamp kit 4000 Series R

T6253/212 Piston crown handle 4000 Series M

T6253/236 Lifting eye 4000 Series R

T6253/238 Circlip pliers - internal 4000 Series R

T6253/295 Piston removal tool for gas 4000 Series M
engines

T85001/33 Gear spacing tool 4000 Series R

T9142/8 Cup plug mandrel 4000 Series R
T6253/121 Pegged Socket 4000 Series R
T431398 PEC Governor Positioning Tool 4000 Series R
( in-line )
T430935 PEC Governor Positioning Tool 4000 Series R
(vee)

99 Note: M – Mandatory R - Recommended

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 Glossary  Contents 

DEF Diesel Exhaust Fluid

ECM Electronic Control Module
ECG Electronic Control Governor
FEOS Front End Oil Seal
FIE Fuel Injection Equipment
ICP Injection Control Pressure
IOPU . Industrial Open Power Unit
REOS Rear End Oil Seal
TDC Top Dead Centre

100
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