2. Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
This document has been printed from SPI². Not for Resale
3. SENR9835-02 3
Table of Contents
Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump and Fuel Filter Base - Remove
and Install ........................................................... 4
Fuel Injection Lines - Remove and Install (Naturally
Aspirated Engines) .............................................. 5
Fuel Injection Lines - Remove and Install
(Turbocharged Engines) ..................................... 6
Fuel Injection Pump - Remove ............................ 8
Fuel Injection Pump - Install ................................ 9
Turbocharger - Remove ........................................ 10
Fuel Injector - Remove (Turbocharged Engines) .. 11
Fuel Injector - Remove (Naturally Aspirated
Engines) .............................................................. 11
Fuel Injector - Install (Turbocharged Engines) ...... 12
Fuel Injector - Install (Naturally Aspirated
Engines) .............................................................. 12
Turbocharger - Install ............................................ 13
Exhaust Manifold - Remove and Install ............... 13
Inlet Manifold - Remove ....................................... 14
Inlet Manifold - Install ........................................... 15
Inlet and Exhaust Valve Springs - Remove and Install
(Installed Cylinder Head) .................................... 15
Inlet and Exhaust Valves - Remove and Install .... 17
Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 19
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 21
Engine Oil Filter Base - Remove and Install ........ 21
Engine Oil Cooler - Remove ................................. 22
Engine Oil Cooler - Install ..................................... 23
Engine Oil Relief Valve - Remove and Install ....... 24
Engine Oil Bypass Valve - Remove and Install ..... 24
Engine Oil Pump - Remove .................................. 25
Engine Oil Pump - Install ...................................... 26
Water Pump - Remove and Install ....................... 26
Water Temperature Regulator Housing - Remove and
Install .................................................................. 27
Flywheel - Remove ............................................... 28
Flywheel - Install ................................................... 29
Crankshaft Rear Seal - Remove ........................... 30
Crankshaft Rear Seal - Install ............................... 30
Crankshaft Wear Sleeve (Rear) - Remove ........... 31
Crankshaft Wear Sleeve (Rear) - Install ............... 31
Flywheel Housing - Remove and Install .............. 32
Crankshaft Pulley - Remove and Install ............... 33
Crankshaft Front Seal - Remove .......................... 34
Crankshaft Front Seal - Install .............................. 34
Front Cover - Remove and Install ......................... 35
Idler Gear - Remove and Install ............................ 36
Housing (Front) - Remove .................................... 37
Housing (Front) - Install ........................................ 38
Crankcase Breather - Remove and Install ........... 38
Valve Mechanism Cover - Remove and Install ..... 39
Rocker Shaft and Pushrod - Remove ................... 40
Rocker Shaft - Disassemble ................................ 41
Rocker Shaft - Assemble ..................................... 41
Rocker Shaft and Pushrod - Install ....................... 42
Cylinder Head - Remove ...................................... 42
Cylinder Head - Install .......................................... 43
Lifter Group - Remove and Install ......................... 45
Camshaft - Remove and Install ........................... 45
Camshaft Gear - Remove and Install .................. 47
Camshaft Bearings - Remove and Install ............ 47
Engine Oil Pan - Remove and Install ................... 48
Balancer - Remove (If equipped) .......................... 50
Balancer - Install ................................................... 52
Pistons and Connecting Rods - Remove .............. 54
Pistons and Connecting Rods - Disassemble ....... 55
Pistons and Connecting Rods - Assemble ........... 56
Pistons and Connecting Rods - Install .................. 57
Connecting Rod Bearings - Remove .................... 58
Connecting Rod Bearings - Install ........................ 59
Crankshaft Main Bearings - Remove .................... 59
Crankshaft Main Bearings - Install ........................ 61
Crankshaft - Remove ............................................ 63
Crankshaft - Install ................................................ 64
Crankshaft Gear - Remove and Install ................ 66
Bearing Clearance - Check ................................... 67
Coolant Temperature Switch - Remove and
Install ................................................................... 68
Engine Oil Pressure Switch - Remove and Install
............................................................................. 69
Glow Plugs - Remove and Install (Naturally Aspirated
Engines) .............................................................. 70
Glow Plugs - Remove and Install (Turbocharged
Engines) .............................................................. 70
V-Belts - Remove and Install ................................ 71
Fan - Remove and Install ..................................... 72
Alternator - Remove .............................................. 73
Alternator - Install .................................................. 73
Electric Starting Motor - Remove and Install ....... 74
Index Section
Index ..................................................................... 75
This document has been printed from SPI². Not for Resale
4. 4 SENR9835-02
Disassembly and Assembly Section
Disassembly and Assembly
Section
i01967847
Fuel Priming Pump and Fuel
Filter Base - Remove and
Install
Removal Procedure
Note: Put identification marks on all hose assemblies
and on all tube assemblies for installation purposes.
Plug all hose assemblies and tube assemblies.
This helps prevent fluid loss, and this helps to keep
contaminants from entering the system.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01002410
Illustration 1
1. Disconnect the tube assemblies for the fuel inlet
and the fuel outlet from the fuel filter base.
2. Disconnect the fuel return line from the fuel filter
base.
3. Disconnect the harness assembly from the fuel
priming pump.
4. Remove the setscrews that hold fuel filter base
(1). Remove the fuel filter base (1).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01002410
Illustration 2
Note: The fuel filter is remotely mounted by the OEM
and the torques for the mounting setscrews (1) may
vary. Check with the OEM for the correct torque
setting.
1. Position the fuel filter base (1) and install the
setscrews. Tighten the setscrews evenly.
2. Connect the tube assemblies for the fuel inlet and
the fuel outlet to the fuel filter base.
3. Connect the fuel return line to the fuel filter base.
4. Connect the harness assembly to the fuel priming
pump.
5. Remove the air from the fuel system. Refer to
Operations and Maintenance Manual, “Fuel
System - Prime”.
This document has been printed from SPI². Not for Resale
5. SENR9835-02 5
Disassembly and Assembly Section
i01972549
Fuel Injection Lines - Remove
and Install
(Naturally Aspirated Engines)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01024434
Illustration 3
Note: If necessary, remove the dipstick tube.
1. Disconnect the fuel injection lines (1) from the fuel
injector (2). Plug all openings immediately.
2. Disconnect the fuel injection lines (1) at the fuel
injection pump (5).
Note: Use two spanner wrenches in order to remove
each fuel injection line (1) at the fuel injection pump
(5). Do not allow each union (4) for the fuel injection
pump to turn.
3. Remove the fuel injection lines (1) from the engine.
Note: If necessary, loosen the clamps that tie the fuel
injection lines together in order to maneuver the lines
off the engine.
g01024433
Illustration 4
4. Disconnect the union nut (8). Remove the banjo
bolt (11) and remove the sealing washers.
Remove the setscrew for the clamp (10). Remove
the fuel return line (9).
5. Remove the nut (3) from each fuel injector.
Remove the fuel return line (7) from the engine.
Also remove the sealing washers (12) that are
located under the fuel return line (7).
6. Remove the fuel inlet line (6) from the fuel injection
pump (5).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
6. 6 SENR9835-02
Disassembly and Assembly Section
g01024434
Illustration 5
1. Install the new sealing washers (12) onto the fuel
injectors (2). Locate the fuel return line (7) onto
the fuel injectors (2).
g01024433
Illustration 6
2. Install the nuts (3) onto each fuel injector.
Tighten the nuts (3) to a torque of 20 to 24 N·m
(15 to 18 lb ft).
3. Locate the fuel return line (7) onto the engine.
Connect the union nut (8). Install the banjo bolt
(11).
4. Tighten the banjo bolt (11) to a torque of
22 to 31 N·m (16 to 23 lb ft). Install the clamp bolt
(10).
Note: If necessary, replace the sealing washer on
the banjo bolt (11).
5. Position the fuel injection lines (1) on the engine.
6. Connect the fuel injection lines (1) at the fuel
injection pump (5). Tighten the union nuts to a
torque of 27 to 32 N·m (20 to 24 lb ft).
Note: Use two spanner wrenches in order to install
the fuel injection lines (1) at the fuel injection pump
(5). Do not allow the unions (4) for the fuel injection
pump to turn.
7. Connect the fuel injection lines (1) to the fuel
injectors (2). Tighten the union nuts to a torque of
27 to 32 N·m (20 to 24 lb ft).
8. If the clamps that tie the fuel injection lines
together were loosened for removal purposes,
tighten the clamps securely.
9. Install the fuel inlet line (6).
Note: If the dipstick tube was removed, install the
dipstick tube and tighten to 22 N·m (16 lb ft).
i01968274
Fuel Injection Lines - Remove
and Install
(Turbocharged Engines)
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
This document has been printed from SPI². Not for Resale
7. SENR9835-02 7
Disassembly and Assembly Section
g01021961
Illustration 7
Note: If necessary, remove the dipstick tube.
1. Disconnect the fuel injection lines (1) from the fuel
injectors (2). Plug all the openings immediately.
2. Disconnect the fuel injection lines (1) from the fuel
injection pump (6). Plug all openings immediately.
Note: Use two spanner wrenches in order to remove
the fuel injection lines (1) at the fuel injection pump
(6). Do not allow the union (5) for the fuel injection
pump to turn.
3. Remove the fuel injection lines (1) from the engine.
Note: If necessary, loosen the clamps that tie the fuel
injection lines together in order to maneuver the lines
off the engine.
g01023626
Illustration 8
4. Disconnect the fuel hoses (9) from the fuel return
line (10) and disconnect the fuel hose (9) from the
fuel injector (2). Disconnect the hose (13) that
connects the individual injectors (2) to each other.
5. Remove the banjo bolt (12) and the sealing
washers for the banjo bolt from the fuel injection
pump (6).
6. Remove the clamping arrangement (11). Remove
the fuel return line (10) from the engine.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
8. 8 SENR9835-02
Disassembly and Assembly Section
g01021961
Illustration 9
Note: Install the individual fuel hoses (13) between
the fuel injectors. Check that the hose clamps (2)
are secure.
g01023626
Illustration 10
1. Install the fuel hose (9) onto the fuel injector (2).
Locate the fuel return line (10) onto the engine.
2. Connect the fuel hose (9) to the return line (10).
Install the clamp arrangement (11) and install the
banjo bolt (12). Tighten banjo bolt (12) to a torque
of 22 to 31 N·m (16 to 23 lb ft).
Note: If necessary, replace the sealing washers on
the banjo bolt (12). Ensure that all the hose clamps
are secure.
3. Position the fuel injection lines (1) on the engine.
4. Connect fuel injection lines (1) at the fuel injection
pump (6). Tighten the union nuts to a torque of
27 to 32 N·m (20 to 24 lb ft).
Note: Use two spanner wrenches in order to install
the fuel injection lines (1) at the fuel injection pump
(6). Do not allow the union (5) for the fuel injection
pump to turn.
5. Connect the fuel injection lines (1) to the fuel
injectors (2). Tighten the union nuts to a torque of
27 to 32 N·m (20 to 24 lb ft).
6. Install the fuel inlet line to the banjo bolt (7) on the
fuel injection pump (6).
7. If the clamps that tie the fuel injection lines
together were loosened for removal purposes,
tighten the clamps securely.
Note: If the dipstick tube was removed, install the
dipstick tube and tighten to 22 N·m (16 lb ft).
i02295882
Fuel Injection Pump - Remove
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.
b. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: There are two types of fuel injection pump
that may be installed on the engine. The pumps are
manufactured by either Bosch or Denso and the
same process is used to install both pumps.
1. Ensure that the No. 1 cylinder is at the top
center compression stroke. Refer to Testing and
Adjusting, “Finding Top Center Position for No.
1 Piston”.
This document has been printed from SPI². Not for Resale
9. SENR9835-02 9
Disassembly and Assembly Section
2. Disconnect the connection to the fuel shutoff
solenoid.
g01002553
Illustration 11
3. Remove setscrew (5) that secures the fuel
injection pump (1) to the support bracket. Remove
the setscrew (4) from the flange.
4. Remove the fuel injection pump (1) from the front
housing.
5. Remove the nut (2) from the shaft of fuel injection
pump (1).
Note: Ensure that the fuel injection pump is correctly
supported before removing the nut for the fuel
injection pump gear.
6. Use a suitable tool to remove the fuel injection
pump gear (3).
7. Remove the O-ring seal from the flange.
Note: Check the condition of the O-ring seal for wear
or damage. Replace the O-ring seal, if necessary.
8. If a Denzo fuel injection pump was installed on the
engine, remove the two nuts from the studs that
secure the flange to the fuel injection pump body.
Remove the joint. Discard the joint.
9. If a Bosch fuel injection pump was installed on the
engine, remove the three nuts from the studs that
secure the flange to the fuel injection pump body.
Remove the joint. Discard the joint.
i01976208
Fuel Injection Pump - Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the No. 1 cylinder is at the top
center compression stroke. Refer to Testing and
Adjusting, “Finding Top Center Position for No.
1 Piston”.
g01002553
Illustration 12
2. Install a new joint on the flange. Position the
flange on the fuel injection pump (1). If aBoschfuel
injection pump was removed, install the three nuts
that secure the flange to the fuel injection pump
and tighten evenly to 22 N·m (16 lb ft).
If a Denso fuel injection pump was removed,
install the two nuts that secure the flange to the
fuel injection pump and tighten evenly to 22 N·m
(16 lb ft).
3. Position the O-ring seal on the flange of the fuel
injection pump.
Note: Ensure that the mating surfaces of the fuel
injection pump gear and the shaft of the fuel injection
pump are clean. Lubricate the threads of the shaft for
the fuel injection pump. The nut must turn freely until
contact is made with the fuel injection pump gear.
4. Install fuel injection pump gear (3) to the shaft of
the fuel injection pump (1).
Note: Be sure that the fuel injection pump is properly
supported before installing the nut for the fuel
injection pump gear.
This document has been printed from SPI². Not for Resale
10. 10 SENR9835-02
Disassembly and Assembly Section
5. Install the nut (2) and tighten the nut to the
following torque:
Naturally aspirated engines ............. 59 to 69 N·m
(43 to 51 lb ft)
Turbocharged engines ..................... 83 to 98 N·m
(61 to 72 lb ft)
6. Position the fuel injection pump (1) to the front
housing of the engine. Install the setscrew (4)
and tighten securely. Install the setscrew (5) for
the support bracket and tighten evenly to 22 N·m
(16 lb ft).
7. Install the connection to the fuel shutoff solenoid.
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”.
b. Install the fuel injection lines. Refer to Disassembly
and Assembly, “Fuel Injection Lines - Remove
and Install”.
i01974273
Turbocharger - Remove
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g00999677
Illustration 13
1. Loosen the hose clamps (5) and remove the air
inlet hose (3) from the inlet manifold and from the
air pipe (2).
2. Remove the setscrews (4). Remove the air pipe
(2) and the gasket (1) from the turbocharger
compressor housing.
g01025765
Illustration 14
3. Remove the banjo bolt (6) and the sealing
washers (7). Remove the oil supply tube assembly
(8) from the turbocharger (20).
4. Remove the setscrews (14). Remove the oil drain
tube assembly (13) and the joint (15) from the
turbocharger.
5. If necessary, loosen the hose clamps (11) and
remove the setscrew (12) in order to remove the
oil supply tube assembly (8) and the oil drain tube
assembly (13) from the cylinder block.
This document has been printed from SPI². Not for Resale
11. SENR9835-02 11
Disassembly and Assembly Section
6. If necessary, remove studs (19) from the
turbocharger housing.
7. Remove the locknuts (18). Remove the
turbocharger (20) and the joint (17) from the
exhaust manifold.
8. If necessary, remove the studs (16) from the
exhaust manifold.
9. Plug the oil supply and the oil drain ports of the
turbocharger.
i01974250
Fuel Injector - Remove
(Turbocharged Engines)
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01002464
Illustration 15
1. Remove the setscrew (1). Remove the clamp (2)
from the fuel injector (3).
2. Remove the fuel injector (3) and sealing washer
(4) from the cylinder head.
3. Repeat the procedure in order to remove the
remaining fuel injectors.
i01974249
Fuel Injector - Remove
(Naturally Aspirated Engines)
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, “Fuel Injection Lines
- Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01002452
Illustration 16
1. Remove the fuel injector (1) and the sealing
washer (2) from the cylinder head.
This document has been printed from SPI². Not for Resale
12. 12 SENR9835-02
Disassembly and Assembly Section
2. Repeat the procedure in order to remove the
remaining fuel injectors.
i01974251
Fuel Injector - Install
(Turbocharged Engines)
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01002464
Illustration 17
1. Position the sealing washer (4) onto the fuel
injector (3).
2. Position the fuel injector (3) into the cylinder head.
3. Position the clamp (2) onto the fuel injector.
Install the setscrew (1) and tighten to a torque of
21 to 23 N·m (16 to 17 lb ft).
4. Repeat the procedure in order to install the
remaining fuel injectors.
End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, “Fuel Injection Lines - Remove
and Install”.
i01976055
Fuel Injector - Install
(Naturally Aspirated Engines)
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01002452
Illustration 18
1. Position the washer (2) onto the fuel injector (1).
2. Install the fuel injector (1) into the cylinder
head and tighten to a torque of 53 to 65 N·m
(40 to 48 lb ft).
3. Repeat the procedure in order to install the
remaining fuel injectors (1).
End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, “Fuel Injection Lines - Remove
and Install”.
This document has been printed from SPI². Not for Resale
13. SENR9835-02 13
Disassembly and Assembly Section
i01978805
Turbocharger - Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Clean the mating surfaces of the exhaust manifold
and the turbocharger. Clean the mating surfaces
of the turbocharger and the oil supply tube
assembly and the oil drain tube assembly.
2. Ensure that the turbocharger inlet and outlet
ports are clean and free from restrictions. The
turbocharger shaft must rotate freely.
g00999706
Illustration 19
3. If necessary, install studs (13) in the exhaust
manifold. Install gasket (10) over the studs.
Note: Do not use any sealant on the gasket.
4. Position turbocharger (6) on the exhaust manifold.
5. Apply a suitable anti-seize compound to the
threads of studs (13). Install locknuts (9) and
tighten evenly.
6. Position a new gasket (14) and oil drain tube
assembly (15) on the bottom of the turbocharger.
Tighten bolts (16) evenly to 22 N·m (16 lb ft).
7. If necessary, install oil drain tube assembly (15)
to the cylinder block. Tighten hose clamps (18)
securely.
8. Position new sealing washers (12) and oil supply
tube assembly (11) on the turbocharger. Install
banjo bolt(8) and tighten securely.
9. If necessary, install oil supply tube assembly (11)
to the cylinder block and tighten the bolts evenly.
Install bolt (17) and the clamp in order to secure
the two tube assemblies (11) and (15) together.
10. If necessary, install studs (7) in the turbocharger
housing.
g00999677
Illustration 20
11. Install gasket (1) and air pipe (2) on the
turbocharger compressor housing. Install bolts (4)
and tighten evenly to 22 N·m (16 lb ft).
12. Install air inlet hose (3) on the air inlet manifold
and on air pipe (2). Tighten hose clamps (5)
securely.
i01978806
Exhaust Manifold - Remove
and Install
Removal Procedure
Start By:
a. Remove the turbocharger, if equipped. Refer
to Disassembly and Assembly, “Turbocharger -
Remove”.
Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
14. 14 SENR9835-02
Disassembly and Assembly Section
g00998953
Illustration 21
1. Remove the setscrews (1) that secure the exhaust
manifold (2) to the cylinder head. Begin at the
ends of the exhaust manifold (2) and work toward
the center.
2. Remove the exhaust manifold (2) from the cylinder
head.
3. Remove the joint (3) from the cylinder head.
Discard the joint.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01000656
Illustration 22
1. Clean the flange face of the cylinder head. Install a
guide stud “M8 x 1.25 by 100 mm” into the cylinder
in order to align with the holes (X). Position a new
joint (3) on the guide studs.
Note: Do not use any sealant on the joint.
2. Position the exhaust manifold (2) on the guide
studs.
3. Ensure that all of the setscrews (1) are clean.
Install the setscrews (1) into the holes that do not
have a guide stud. Remove the guide stud and
install the remainder of the setscrews (1).
4. Begin at the center of the exhaust manifold and
work toward the ends. Tighten the setscrews to
the following torque:
Naturally aspirated engines ............. 15 to 22 N·m
(11 to 16 lb ft)
Turbocharged engines ..................... 28 to 33 N·m
(21 to 24 lb ft)
End By:
a. Install the turbocharger, if equipped. Refer to
Disassembly and Assembly, “Turbocharger -
Install”.
i02001084
Inlet Manifold - Remove
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. If the engine is equipped with a turbocharger,
remove the air inlet hose that is above the valve
mechanism cover. Refer to Disassembly and
Assembly, “Turbocharger - Remove”.
g01001495
Illustration 23
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16. SENR9835-02 15
Disassembly and Assembly Section
2. Remove the setscrews (4) from the inlet manifold
(3).
3. Remove the inlet manifold (3) and the gasket (1)
from the cylinder head. Discard the gasket.
4. If necessary, remove the setscrews for the air inlet
elbow (2). Remove the air inlet elbow (2) and the
gasket from the inlet manifold (3).
i02001105
Inlet Manifold - Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that all the mounting surfaces are clean
and free from debris.
g01001495
Illustration 24
2. If necessary, position a new gasket and the air
inlet elbow (2) onto the inlet manifold (3). Install
the setscrews and tighten evenly.
3. Position the gasket (1) onto the back of the inlet
manifold (3).
4. Position the inlet manifold (3) onto the cylinder
head.
5. Install the setscrews (4) and tighten evenly.
6. If the engine is equipped with a turbocharger,
install the air inlet hose that is above the valve
mechanism cover. Refer to Disassembly and
Assembly, “Turbocharger - Install”.
i01978832
Inlet and Exhaust Valve
Springs - Remove and Install
(Installed Cylinder Head)
Removal Procedure
Table 1
Required Tools
Part
Number
Part Description Qty
21825666 Valve Spring Compressor 1
21825931 Stud Adapter 1
21825932 Setscrew Adapter 1
27610261 Installer for the Valve Stem Seal 1
Start By:
a. Remove the fuel injectors. Refer to Disassembly
and Assembly, “Fuel Injector - Remove (Naturally
Aspirated Engines) ” and Disassembly and
Assembly, “Fuel Injector - Remove (Turbocharged
Engines) ”.
b. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: The following procedure is for the removal
of the inlet and exhaust valve springs without
removing the cylinder head. Perform the removal
and installation procedures for one cylinder at a
time in order to avoid dropping a valve into the
engine.
Note: Before you begin the removal of the valve
springs, refer to Specifications, “Cylinder Head
Valves” for appropriate information on the valve
springs.
1. Ensure that the piston is at the top center position.
Note: If the rocker shaft assembly has been
removed, use the following procedure in order to find
the top center position. Go to Step 2 if the rocker arm
assembly is installed.
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17. 16 SENR9835-02
Disassembly and Assembly Section
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
g01038636
Illustration 25
Personal injury can result from being struck by
parts propelled by a released spring force.
Make sure to wear all necessary protective equip-
ment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
a. Install the 21825666 Valve Spring Compressor
with the 21825931 Adapter for the Valve
Spring or the 21825932 Adapter for the
Setscrew .
b. Compress the valve spring in order to open
the valve.
c. Turn the crankshaft until the piston touches
the valve.
d. Continue to turn the crankshaft and release the
pressure of the Valve Spring Compressor until
the piston is at the Top Center position.
2. Use the Valve Spring Compressor in order to
compress the valve spring (4). Use a suitable
magnetic tool to remove the valve caps (1) and
the valve keepers (2).
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
3. Carefully release all the pressure on the Valve
Spring Compressor . Remove the valve spring
retainer (3) and the valve spring (4).
4. If it is necessary, use a suitable tool to remove the
valve stem seals.
Note: If you are replacing all of the valve springs, the
procedure can be done on two cylinders at the same
time. The procedure can be done on cylinder 1 and
cylinder 4, and on cylinder 2 and cylinder 3.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Installation Procedure
Table 2
Required Tools
Part Number Part Description Qty
21825666 Valve Spring Compressor 1
21825931 Adapter for the stud 1
21825932
Adapter for the setscrew
1
27610261 Installer for the Valve Stem Seal 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
1. Use the 27610261 Installer for the Valve Stem
Seals to install the new valve stem seals into the
cylinder head (not shown).
2. Place the new valve spring (4) into position.
This document has been printed from SPI². Not for Resale
