800D Industrial Engines

KENR6241
August 2007
Disassembly and
Assembly
800D Series Industrial Engine
UK (Engine)
UL (Engine)
This document has been printed from SPI. Not for Resale
Important Safety Information

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

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

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
KENR6241
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) ....................................... 7
Fuel Injection Pump - Remove .............................. 9
Fuel Injection Pump - Remove (Fuel Injection Pumps
With a Water Heated Cold Start Device) .............. 11
Fuel Injection Pump - Install (Fuel Injection Pumps
With a Water Heated Cold Start Device) ............. 13
Fuel Injection Pump - Install ................................ 14
Fuel Injector - Remove and Install (Naturally
Aspirated Engines) .............................................. 16
Fuel Injector - Remove and Install (Turbocharged
Engines) .............................................................. 16
Turbocharger - Remove ........................................ 17
Turbocharger - Install ............................................ 19
Exhaust Manifold - Remove and Install ............... 20
Inlet Manifold - Remove and Install ..................... 21
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 23
Inlet and Exhaust Valves - Remove and Install .... 25
Engine Oil Filter Base - Remove and Install ........ 28
Engine Oil Cooler - Remove ................................. 29
Engine Oil Cooler - Install ..................................... 30
Engine Oil Relief Valve - Remove and Install ....... 31
Engine Oil Bypass Valve - Remove and Install ..... 32
Engine Oil Pump - Remove .................................. 33
Engine Oil Pump - Install ...................................... 34
Water Pump - Remove and Install ....................... 35
Water Temperature Regulator Housing - Remove and
Install .................................................................. 37
Flywheel - Remove ............................................... 38
Flywheel - Install ................................................... 39
Crankshaft Rear Seal - Remove and Install ......... 40
Crankshaft Wear Sleeve (Rear) - Remove and
Install ................................................................... 42
Flywheel Housing - Remove and Install .............. 43
Crankshaft Pulley - Remove and Install ............... 45
Crankshaft Front Seal - Remove and Install ......... 47
Front Cover - Remove and Install ......................... 48
Idler Gear - Remove and Install ............................ 48
Housing (Front) - Remove and Install ................... 51
Front Plate - Remove ............................................ 52
Front Plate - Install ................................................ 53
Crankcase Breather - Remove and Install
(Turbocharged Engines) ..................................... 54
Valve Mechanism Cover - Remove and Install ..... 55
Rocker Shaft and Pushrod - Remove ................... 56
Rocker Shaft - Disassemble ................................ 57
Rocker Shaft - Assemble ..................................... 58
Rocker Shaft and Pushrod - Install ....................... 59
Cylinder Head - Remove ...................................... 60
Cylinder Head - Install .......................................... 62
Lifter Group - Remove and Install ......................... 64
Camshaft - Remove and Install ........................... 65
3
Table of Contents
Camshaft Gear - Remove and Install .................. 66

Engine Oil Pan - Remove and Install ................... 67
Balancer - Remove ............................................... 70
Balancer - Disassemble ........................................ 71
Balancer - Assemble ............................................. 72
Balancer - Install ................................................... 73
Pistons and Connecting Rods - Remove .............. 74
Pistons and Connecting Rods - Disassemble ....... 75
Pistons and Connecting Rods - Assemble ........... 77
Pistons and Connecting Rods - Install .................. 80
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................... 81
Connecting Rod Bearings - Install (Connecting rods
in position) ........................................................... 82
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position) ....................................... 83
Crankshaft - Remove ............................................ 87
Crankshaft - Install ................................................ 89
Crankshaft Gear - Remove and Install ................ 92
Bearing Clearance - Check ................................... 93
Coolant Temperature Sensor - Remove and
Install ................................................................... 94
Engine Oil Pressure Sensor - Remove and Install
............................................................................. 94
Glow Plugs - Remove and Install ......................... 95
V-Belts - Remove and Install ................................ 97
Fan - Remove and Install ..................................... 97
Alternator - Remove and Install ........................... 98
Electric Starting Motor - Remove and Install ..... 100
Index Section
Index ................................................................... 101
4
KENR6241
Disassembly and Assembly

Section
i02748528
Fuel Priming Pump and Fuel

Filter Base - Remove and
Install
Removal Procedure
Illustration 1
g01324908
Typical example
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
3. Drain fuel filter (4). Refer to Operation and

Maintenance Manual, Fuel System Primary
Filter/Water Seperator - Drain.
4. Disconnect harness assembly (1) from fuel
priming pump (2).
5. Disconnect the tube assemblies (not shown) from
fuel filter base (3).
6. Remove bolts (5) and remove fuel filter base (3).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
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.
1. Turn the fuel supply to the OFF position.
Installation Procedure
NOTICE
component life.
1. Ensure that the assembly of the fuel priming pump
and the fuel filter base is clean and free from
damage. If necessary, replace any components
that are damaged.
2. Turn the battery disconnect switch to the OFF

position.
Illustration 2
g01324908
Typical example
KENR6241
5
2. Position fuel filter base (3) on the mounting

bracket. Install bolts (5) to the fuel filter base.
Tighten the bolts to a torque of 35 Nm (26 lb ft).
3. Connect the tube assemblies for the fuel inlet and
the fuel outlet (not shown) to fuel filter base (3).
4. If necessary, install a new fuel filter (4) to fuel filter
base (3). Refer to Operation and Maintenance
Manual, Fuel System Primary Filter/Water
Seperator - Drain.
5. Connect harness assembly (1) to fuel priming
pump (2).
6. Turn the fuel supply to the ON position.
7. Turn the battery disconnect switch to the ON
position.
8. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, Fuel System
- Prime.
Illustration 3
g01332971
Typical example
i02748531
Fuel Injection Lines - Remove

and Install
(Naturally Aspirated Engines)
Removal Procedure
NOTICE
mandates.
NOTICE
component life.
Illustration 4
g01332972
Typical example
Note: Place identification marks on all tube

assemblies for installation. Plug all lines and tube
assemblies in order to prevent contamination.
2. If necessary, loosen the dipstick tube (not shown).
3. Disconnect hose (4) from tube assembly (6).

4. Disconnect fuel injection lines (1) from fuel
injectors (3).
injection pump (5).
6
KENR6241
Note: Do not allow the unions to turn in the fuel

injection pump when the fuel line nuts are loosened.
Use two wrenches in order to disconnect the fuel
injection lines from the fuel injection pump.
6. Remove fuel injection lines (1).
7. Use suitable caps in order to plug the open ports
of the fuel injection pump immediately.
8. Disconnect tube assembly (6) from fuel return line
(2).
9. Remove banjo bolt (9) and sealing washers (10)
from fuel injection pump (5).
10. Remove bolt (11) and remove tube assembly (6).
11. Remove nuts (7) from fuel injectors (3). Remove
fuel return line (2) and sealing washers (8) from
fuel injectors (3).
of the fuel injectors immediately.
Illustration 5
g01332971
Typical example
Table 1
Required Tools
Tool
Part Number
Part Description
Qty
27610294
Injector Pipe Nut Tool
NOTICE
component life.
Illustration 6
g01332972
Typical example
1. Remove the caps from fuel injectors (3) and install

new sealing washers (8) to the fuel injectors.
Note: Washers (8) have two small holes. The position
of the holes is not important.
KENR6241
7
2. Position fuel return line (2) onto fuel injectors (3).

3. Install nuts (7) onto each fuel injector. Tighten the
nuts to a torque of 23 Nm (17 lb ft).
4. Position tube assembly (6) onto the engine.
Loosely connect the tube assembly to fuel return
line (2).
5. Install banjo bolt (9) and new sealing washers (10)
to fuel injection pump (5).
6. Install bolt (11). Tighten the bolt to a torque of
11 Nm (97 lb in).
NOTICE
component life.
Note: Place identification marks on all tube
assemblies for installation. Plug all lines and tube
assemblies in order to prevent contamination.
7. Tighten banjo bolt (9) to a torque of 18 Nm

(13 lb ft). Tighten the nut to fuel return line (2) to a
torque of 20 Nm (15 lb ft).
8. Remove the caps from the fuel injection pump.
Install fuel injection lines (1) to fuel injection pump
(5) and to fuel injectors (3).
9. Use Tooling (A) to tighten the nuts on fuel injection
lines (1) to a torque of 30 Nm (22 lb ft).
injection pump when the fuel line nuts are tightened.
10. Connect hose (4) to tube assembly (6).
11. If necessary, tighten the dipstick tube (not shown)
to a torque of 9 Nm (80 lb in).
13. Prime the fuel system. Refer to Operation and
Maintenance Manual, Fuel System - Prime for
more information.
i02748529
Fuel Injection Lines - Remove

and Install
(Turbocharged Engines)
Illustration 7
g01332532
Typical example
Removal Procedure
NOTICE
mandates.
8
KENR6241
Table 2
Required Tools
Tool
Part Number
Part Description
Qty
27610294
Injector Pipe Nut Tool
NOTICE
component life.
Illustration 8
g01324910
Typical example
2. If necessary, loosen the dipstick tube (not shown).

injectors (3).
injection pump (5).
injection pump when the fuel line nuts are loosened.
Use two wrenches in order to disconnect the fuel
injection lines from the fuel injection pump.
5. Remove clamps (4) and remove fuel injection
lines (1).
Illustration 9
g01332532
Typical example

of the fuel injection pump and the fuel injectors
immediately.
7. Disconnect tube assembly (6) from fuel injector
(3). Disconnect tube assembly (6) from fuel
injection pump (5). Remove bolts (7) and remove
tube assembly (6).
8. Remove hoses (2) from fuel injectors (3).
KENR6241
9
i02748534
Fuel Injection Pump - Remove

Removal Procedure
Table 3
Required Tools
Tool
Part
Number
Part Description
Combination Puller
Qty
1
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, Fuel Injection Lines
- Remove and Install.
Illustration 10
g01324910
NOTICE
Typical example
1. Install hoses (2) to fuel injectors (3).

mandates.
2. Position tube assembly (6) onto the engine and

install bolts (7). Tighten the bolts to a torque of
18 Nm (13 lb ft).
NOTICE
3. Connect tube assembly (6) to fuel injectors (3).

Connect tube assembly (6) to fuel injection pump
(5).
4. Remove the caps from fuel injectors and from the
fuel injection pump. Loosely install fuel injection
lines (1) to fuel injection pump (5) and to fuel
injectors (3).

component life.
1. Ensure that number one piston is at the top
center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting,
Finding Top Center Position for No. 1 Piston.
5. Install clamps (4). Tighten the clamps securely.

6. Use Tooling (A) to tighten the nuts on fuel injection
lines (1) to a torque of 30 Nm (22 lb ft).
injection pump when the fuel line nuts are tightened.
7. If necessary, tighten the dipstick tube (not shown)
9. Prime the fuel system. Refer to Operation and
Maintenance Manual, Fuel System - Prime for
more information.
10
Illustration 11
KENR6241
g01335768
Illustration 13
g01375471
Typical example
Typical example
2. Remove bolts (4).
6. Loosen bolt (7).
3. Remove plate (2) from front housing (1).
7. Remove fasteners (8), bolt (10) and bracket (9).
4. Remove O-ring seal (3) from plate (2).
8. Support fuel injection pump (6) and remove bolt

(7).
9. Remove the assembly of housing (5) and fuel
injection pump (6).
Illustration 12
g01375914
Timing marks on the gears
5. Ensure that Timing marks (X) on the teeth of the

gears are aligned or make temporary marks on
the gears for installation purposes.
Illustration 14
g01335808
Typical example
10. Remove O-ring seal (13) from housing (5).

11. Loosen nut (11).
KENR6241
11
Note: Do not remove the nut at this time.

12. Use Tooling (A) to loosen gear (12). Remove nut
(11) and gear (12).
1. Drain the coolant from the cooling system into a

suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, Cooling
System Coolant - Change for more information.
13. If the original fuel injection pump will be installed,

mark the flange of fuel injection pump (6) and
housing (5). Remove nuts (15).
Note: Refer to Systems Operation, Testing and
Adjusting, Fuel Injection Timing - Check for the
correct method of setting the fuel injection pump
timing after installation.
14. Remove housing (5) from fuel injection pump (6).
Remove O-ring seal (14) from housing (5).
i02748532
g01366198
Fuel Injection Pump - Remove

(Fuel Injection Pumps With
a Water Heated Cold Start
Device)
Illustration 15
Removal Procedure

Table 4
Required Tools
Tool
Part Number
Part Description
Combination Puller
Typical example
2. Loosen the hose clamps and disconnect hoses (1)

and (4) from fuel injection pump (2).
3. Loosen the hose clamps and remove hose (3)
from fuel injection pump (2).
Qty
1
Start By:
NOTICE
mandates.
Illustration 16
NOTICE
component life.
g01366190
Typical example

12
Illustration 17
KENR6241
g01375914
8. Ensure that Timing marks (X) on the teeth of the

gears are aligned or make temporary marks on
the gears for installation purposes.
Illustration 19
g01375949
Typical example
13. Remove O-ring seal (16) from housing (9).

14. Loosen nut (14).
15. Use Tooling (A) to loosen gear (15). Remove nut
(14) and gear (15).
16. If the original fuel injection pump will be installed,
mark the flange of fuel injection pump (2) and
housing (9). Remove nuts (18).
Note: Refer to Systems Operation, Testing and
Adjusting, Fuel Injection Timing - Check for the
correct method of setting the fuel injection pump
timing after installation.
Illustration 18
g01375476
Typical example
17. Remove housing (9) from fuel injection pump (2).

Remove O-ring seal (17) from housing (9).
9. Loosen bolt (10).

10. Remove fasteners (11), bolt (13) and bracket (12).
11. Support fuel injection pump (2) and remove bolt
(10).
12. Remove the assembly of housing (9) and fuel
injection pump (2).
KENR6241
13
i02748536
Fuel Injection Pump - Install

(Fuel Injection Pumps With
a Water Heated Cold Start
Device)
6. Install a new O-ring seal (16) to housing (9). Install

gear (15) to fuel injection pump (2). Install nut (14)
finger tight.
NOTICE
component life.
Illustration 21
g01375476
Typical example
Illustration 22
g01375914

Illustration 20
g01375949
Typical example
2. Ensure that the mating surfaces of housing (9)

and fuel injection pump (2) are clean and free
from damage.
3. Install a new O-ring seal (17) to housing (9).
4. Position housing (9) on fuel injection pump (2). If
the original fuel injection pump is installed, ensure
that the appropriate marks on the flange of the
fuel injection pump and the housing are aligned.
Install nuts (18) finger tight.
7. Install the assembly of housing (9) and fuel

injection pump (2) to the engine. Ensure that
Timing marks (X) on the teeth of the gears are in
the correct position. Install bolt (10) finger tight.
8. Position bracket (12) on fuel injection pump (2).
Install fasteners (11) and bolt (13) finger tight.
9. Tighten nut (14) to a torque of 90 Nm (66 lb ft).
Refer to Illustration 20.
5. Tighten nuts (18) to a torque of 18 Nm (13 lb ft).
14
KENR6241
15. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, Cooling
System Coolant - Change for the correct
procedure.
16. Adjust the fuel injection pump timing. Refer to
Systems Operation, Testing and Adjusting, Fuel
Injection Timing - Check.
End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection Lines - Remove
and Install.
i02748535
Fuel Injection Pump - Install

Illustration 23
g01366190
Typical example
10. Install a new O-ring seal (7) to plate (6).
NOTICE
11. Position plate (6) on front housing (5). Install

bolts (8). Tighten the bolts to a torque of 18 Nm
(13 lb ft).

component life.
12. Tighten bolt (10) to a torque of 18 Nm (13 lb ft).

Tighten bolt (13) to a torque of 18 Nm (13 lb ft).
Tighten fasteners (11) to a torque of 35 Nm
(26 lb ft). Refer to Illustration 21.

Illustration 24
g01366198
Typical example
13. Install hose (3) to fuel injection pump (2). Tighten

the hose clamps securely.
14. Connect hoses (1) and (4) to fuel injection pump
(2). Tighten the hose clamps securely.
Illustration 25
g01335808
Typical example
KENR6241
15
2. Ensure that the mating surfaces of housing (5)

and fuel injection pump (6) are clean and free
from damage.
3. Install a new O-ring seal (14) to housing (5).
8. Position bracket (9) on fuel injection pump (6).

Install fasteners (8) and bolt (10) finger tight.
9. Tighten nut (11) to a torque of 90 Nm (66 lb ft).
Refer to Illustration 25.
4. Position housing (5) on fuel injection pump (6). If

the original fuel injection pump is installed, ensure
that the appropriate marks on the flange of the
fuel injection pump and the housing are aligned.
Install nuts (15) finger tight.
5. Tighten nuts (15) to a torque of 18 Nm (13 lb ft).
6. Install a new O-ring seal (13) to housing (5). Install
gear (12) to fuel injection pump (6). Install nut (11)
finger tight.
Illustration 28
g01335768
Typical example

11. Position plate (2) on front housing (1). Install
(13 lb ft).
Illustration 26
g01375471
Typical example

Tighten bolt (10) to a torque of 18 Nm (13 lb ft).
Tighten fasteners (8) to a torque of 35 Nm
(26 lb ft). Refer to Illustration 26.
13. Adjust the fuel injection pump timing. Refer to
Systems Operation, Testing and Adjusting, Fuel
Injection Timing - Check.
End By:
and Install.
Illustration 27
g01375914
7. Install the assembly of housing (5) and fuel

injection pump (6) to the engine. Ensure that
Timing marks (X) on the teeth of the gears are in
the correct position. Install bolt (7) finger tight.
16
KENR6241
i02748539
Fuel Injector - Remove and

Install
(Naturally Aspirated Engines)
NOTICE
component life.
1. Clean the bore for the fuel injector in the cylinder
head. Ensure that no debris enters the cylinder.
Clean the threads on the body of the fuel injector.
Removal Procedure
Start By:
NOTICE
component life.
NOTICE
mandates.
Illustration 30
g01325773
Typical example
2. Install new seat washers (1) into the bore for the
fuel injector in the cylinder head.
3. Install fuel injectors (2) into the cylinder head. Use
a deep socket to tighten fuel injectors (2) to a
End By:
and Install.
i02748538
Illustration 29
g01325773
Fuel Injector - Remove and

Install
Typical example
1. Use a deep socket to remove fuel injectors (2)

from the cylinder head.
2. Remove seat washers (1).
Removal Procedure
Start By:
KENR6241
17
NOTICE
component life.
NOTICE
mandates.
Illustration 32
g01325781
Typical example
2. Install new seat washers (1) to the bores for the

fuel injectors in the cylinder head.
3. Install fuel injectors (2) into the cylinder head.
4. Position clamps (4) onto fuel injectors (2) and
install bolts (3). Tighten bolts (3) to a torque of
22 Nm (16 lb ft).
End By:
and Install.
Illustration 31
g01325781
1. Remove bolts (3) and clamps (4) from fuel

injectors (2).
i02748540
Turbocharger - Remove
2. Remove fuel injectors (2) from the cylinder head.

3. Remove seat washers (1).
Removal Procedure
NOTICE
NOTICE

component life.

component life.
1. Clean the bores for the fuel injectors in the cylinder
head. Ensure that no debris enters the cylinders.
Clean the fuel injectors.
NOTICE
mandates.
18
Illustration 33
KENR6241
g01336694
Typical example
1. Loosen hose clamps (6) and remove hose (4).

Plug the connection on the inlet manifold with a
suitable plug.
2. Remove bolts (5) and remove air pipe (3) from
turbocharger (1). Remove gasket (2).
3. Plug the opening in the inlet manifold and the
opening in the turbocharger with suitable plugs.
Illustration 34
g01336699
Typical example
Illustration 35
g01337174
4. Follow Steps 4.a through 4.c in order to remove

tube assembly (9) for the oil feed.
a. Remove tube clamp (17) that secures tube
assembly (9) to tube assembly (12). Note the
position of the clamp.
KENR6241
19
b. Remove banjo bolt (14) and sealing washers

(15). Disconnect tube assembly (9) from
adapter (16) in the cylinder block.
Note: Do not allow adapter (16) to turn in the cylinder
block when the banjo bolt is loosened. Use two
wrenches in order to disconnect the tube assembly.
c. Remove banjo bolt (7) and sealing washers (8).
Remove tube assembly (9) from turbocharger
(1).
5. Follow Steps 5 through 5.c in order to remove the
tube assembly (12) for the oil drain.
a. Remove bolts (13). Disconnect tube assembly
(12) from turbocharger (1).
b. Remove joint (11).
c. If necessary, loosen the hose clips and remove
tube assembly (12) from the adapter in the
cylinder block.
6. Remove the double nuts (not shown) that secure
turbocharger (1) to the exhaust manifold.
7. Remove turbocharger (1) from the exhaust
manifold. Remove gasket (10).
8. Plug the oil supply and the oil drain ports in
the turbocharger and in the cylinder block with
suitable plugs.
i02748541
2. Clean the mating surface of the exhaust manifold.

Install a new gasket (10) over the studs. Apply
Tooling (A) to the studs.
3. Position turbocharger (1) onto the exhaust

manifold and install the double nuts. Tighten the
nuts to a torque of 18 Nm (13 lb ft).
Table 5
Required Tools
Part
Number
Part Description
CV60889
Anti-Seize Compound
g01336699
Typical example
Turbocharger - Install
Tool
Illustration 36
Qty
1
NOTICE
component life.
1. Ensure that the turbocharger is clean and free
from damage. Inspect the turbocharger for
wear. Refer to Systems Operation, Testing and
Adjusting, Turbocharger - Inspect for more
information. If the turbocharger is worn, the
complete turbocharger must be replaced.
Note: Do not allow the lower nuts to turn when the

upper nuts are tightened.
4. Ensure that tube assemblies (9) and (12) are
clean and free from damage. If necessary, replace
the tube assemblies.
5. Remove the plugs from the ports in the
turbocharger and from the cylinder block.
6. If necessary, install the lower end of tube assembly
(12) to the adapter in the cylinder block. Position a
new joint (11) onto tube assembly (12). Connect
the tube assembly to turbocharger (1) and install
(80 lb in). If necessary, tighten the hose clips.
20
KENR6241
7. Lubricate the bearings of turbocharger (1) with

clean engine oil through the oil inlet port. Rotate
the shaft of the turbocharger in order to distribute
the lubricant.
8. Install new sealing washers (8) and banjo bolt (7)
to tube assembly (9). Position tube assembly (9)
onto turbocharger (1). Tighten the banjo bolt finger
tight. Install new sealing washers (15) and banjo
bolt (14) to tube assembly (9). Connect the tube
assembly to adapter (16) in the cylinder block.
9. Tighten banjo bolts (7) and (14) to a torque of
16 Nm (12 lb ft).
Note: Do not allow adapter (16) to turn in the cylinder
block.
11. Position a new joint (2) and air pipe (3) onto
turbocharger (1). Install bolts (5). Tighten the bolts
to a torque of 18 Nm (13 lb ft).
12. Remove the plugs from the connection on the
inlet manifold and from the turbocharger. Install
hose (4) and tighten hose clamps (6) securely.
i02748542
Exhaust Manifold - Remove

and Install
Removal Procedure
Start By:
a. If the engine is equipped with a turbocharger,
remove the turbocharger. 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.
Illustration 37
g01337174
10. Install clamp (17) to tube assemblies (9) and (12).

Tighten the fasteners securely.
NOTICE
component life.
Illustration 39
g01333088
Exhaust manifold from a naturally aspirated engine
Illustration 38
Typical example
g01336694
1. Loosen bolts (1).

Note: In order to prevent distortion of the exhaust
manifold, Loosen the outer bolts first.
KENR6241
21
2. Remove bolts (1) and remove exhaust manifold

(2) from the cylinder head.
3. Remove gasket (3).
Note: Tighten the center bolts first.

End By:
a. If the engine is equipped with a turbocharger,
install the turbocharger. Refer to Disassembly and
Assembly, Turbocharger - Install.
Table 6
Required Tools
Tool
Part Number
Part Description
Guide Stud
(M8 x 1.25 by 100
mm)
i02748543
Qty
2
Inlet Manifold - Remove and

Install
Removal Procedure
NOTICE
component life.
1. Ensure that the exhaust manifold is clean and
free from damage. Clean the joint surface of the
cylinder head.
Start By:
- Remove and install.
NOTICE
component life.
Illustration 40
g01333101
Exhaust manifold from a naturally aspirated engine
2. Install Tooling (A) to the cylinder head in positions

(X).
3. Position a new exhaust manifold gasket (3) onto
Tooling (A).
Illustration 41
g01333458
Typical example
Note: Ensure that the exhaust manifold gasket is

correctly oriented.
4. Align exhaust manifold (2) with Tooling (A). Install
the exhaust manifold to the cylinder head.
5. Install bolts (1) finger tight.
6. Remove Tooling (A). Install the remaining bolts
(1) finger tight.
7. Tighten bolts (1) to a torque of 30 Nm (22 lb ft).
22
Illustration 42
KENR6241
g01333457
Typical example
Illustration 43
g01333458
Typical example
1. Loosen the hose clamps and disconnect the air

hose (not shown) from connection (3).
2. For naturally aspirated engines, disconnect the
hose for the crankcase breather (not shown) from
inlet manifold (1).
For turbocharged engines, remove the bolt that
secures the hose for the crankcase breather (not
shown) from the inlet manifold (1).
3. Remove bolts (6) from inlet manifold (1). Note the
position of any brackets that are retained by the
bolts for installation.
Illustration 44
4. Remove inlet manifold (1) and gasket (5) from the

cylinder head.
g01333457
Typical example
5. If necessary, remove bolts (4) and remove

connection (3) from inlet manifold (1). Remove
gasket (2).
2. If necessary, position a new gasket (2) and

connection (3) onto inlet manifold (1). Install
(97 lb in).
Note: Ensure correct orientation of the connection.
NOTICE
component life.
1. Ensure that all mating surfaces are clean and free
from debris.
3. Place a new gasket (5) in position on inlet manifold

(1).
4. Position inlet manifold (1) on the cylinder head.
5. Install bolts (6). Ensure that bolts of different
lengths are installed in the correct positions. Also
ensure that any brackets that are retained by the
bolts are installed in the correct positions.
7. For naturally aspirated engines, connect the hose
for the crankcase breather (not shown) to inlet
manifold (1).
KENR6241
23
For turbocharged engines, install the bolt that

secures the hose for the crankcase breather (not
shown) to the inlet manifold (1). Tighten the bolt
8. Connect the air hose (not shown) to connection
(3) and tighten the hose clamps securely.
End By:
and install.
Note: The following procedure should be adopted in

order to remove the valve springs when the cylinder
head is installed to the engine. Refer to Disassembly
and Assembly, Inlet and Exhaust Valves - Remove
and Install for the procedure to remove the valve
springs from a cylinder head that has been removed
from the engine.
Note: Ensure that the appropriate piston is at the top
center position before the valve spring is removed.
Failure to ensure that the piston is at the top center
position may allow the valve to drop into the cylinder
bore.
i02748544
Inlet and Exhaust Valve

Springs - Remove and Install
Removal Procedure
Table 7
Required Tools
Tool
Part
Number
21825666
Valve Spring Compressor
27610235
Adapter
Part Description
Qty
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
NOTICE
component life.
NOTICE
Plug the apertures for the push rods in the cylinder
head in order to prevent the entry of loose parts into
the engine.
Illustration 45
g01358696
Typical example
1. Follow Steps 1.a through 1.d in order to position

the appropriate piston at top center.
a. Install Tooling (A) and (B) in position on the
cylinder head in order to compress a valve
spring for the appropriate piston.
b. Use Tooling (A) in order to compress valve
spring (3) and open the valve slightly.
Note: Do not compress the spring so that the valve
spring retainer (2) touches the valve stem seal.
c. Carefully rotate the crankshaft until the piston
touches the valve.
Note: Do not use excessive force to turn the
crankshaft. The use of force can result in bent valve
stems.
d. Continue to rotate the crankshaft and gradually
release the pressure on Tooling (A) until the
piston is at the top center position. The valve
is now held in a position that allows the valve
spring to be safely removed.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
24
KENR6241
2. Use Tooling (A) in order to compress valve spring

(3). Remove valve keepers (1).
Note: Do not compress the valve spring so that the
valve spring retainer (2) touches the valve stem seal.
3. Slowly release the pressure on Tooling (A).
4. Remove valve spring retainer (2) and remove
valve spring (3).
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
Illustration 46
Note: If all valve springs require replacement the

procedure can be carried out on two cylinders at the
same time. The procedure can be carried out on
the following pairs of cylinders. 1 with 4 and 2 with
3. Ensure that all of the valve springs are installed
before changing from one pair of cylinders to another
pair of cylinders.
5. Remove Tooling (A) and (B).
Typical example
2. Install valve spring (3) onto the cylinder head.

Position valve spring retainer (2) onto valve spring
(3).
Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established

assembly procedure and wear protective equipment.
Table 8
Required Tools
Tool
Part
Number
21825666
Valve Spring Compressor
27610235
Adapter
Part Description
g01358696
Qty
NOTICE
NOTICE
3. Install Tooling (A) and (B) in the appropriate

position on the cylinder head in order to compress
the valve spring.

component life.
4. Apply sufficient pressure to Tooling (A) in order to

install valve keepers (1).
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
1. Inspect the valve springs for the correct length.
Refer to Specifications, Cylinder Head Valves .
Note: Do not compress the spring so that valve

spring retainer (2) touches the valve stem seal.
Install the valve spring keepers.
5. Carefully release the pressure on Tooling (A).
Note: Ensure that the valve keepers are correctly
seated.
KENR6241
25
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
6. Remove Tooling (A). Ensure that all of the valves
are secured in place by a valve spring and valve
keepers. Rotate the crankshaft through about
45 degrees in order to clear the piston from the
valve. Lightly strike the top of the valve with a soft
hammer in order to ensure that the valve keepers
are properly installed.
2. Place a temporary identification mark on the

heads of the valves in order to identify the correct
position.
Note: Do not stamp the heads of the valves.
Stamping or punching the heads of the valves could
cause the valves to fracture.

End By:
a. Install the rocker shaft assembly. Refer to
Pushrod - Install.
NOTICE
i02748545
Inlet and Exhaust Valves Remove and Install

Removal Procedure
Table 9
Required Tools
Tool
Part Number
Part Description
Qty
21825663
Valve Spring
Compressor
Seal Remover
Start By:
a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head Remove.
Illustration 47
g01333469
Typical example
NOTICE
component life.
1. Clean the bottom face of the cylinder head.
Check the depth of the valves below the face of
the cylinder head before the valve springs are
removed. Refer to Specifications, Cylinder Head
Valves for the correct dimensions.
26
KENR6241
NOTICE
component life.
1. Clean all components of the cylinder head
assembly. Ensure that all ports, all coolant
passages and all lubrication passages in the
cylinder head are free from debris. Follow Steps
1.a through 1.e in order to inspect the components
of the cylinder head assembly. Replace any
components that are worn or damaged.
a. Inspect the cylinder head for wear and for
damage. Refer to Systems Operation, Testing
and Adjusting, Cylinder Head Inspect.
g01333471
Illustration 48
Typical example
3. Use Tooling (A) in order to compress the

appropriate valve spring (3). Remove valve
keepers (1).
Note: Do not compress the valve spring so that valve
spring retainer (2) touches valve stem seal (4).
4. Remove Tooling (A).
5. Remove valve spring retainer (2). Remove valve
spring (3).
b. Inspect the valve seats for wear and for

damage. Refer to Specifications, Cylinder
Head Valves for further information.
c. Inspect the valve guides for wear and for
damage. Refer to Specifications, Cylinder
Head Valves and Systems Operation, Testing
and Adjusting, Valve Guide - Inspect for
further information.
d. Inspect the valves for wear and for damage.
Refer to Specifications, Cylinder Head Valves.
e. Inspect the valve springs for the correct length.
Refer to Specifications, Cylinder Head Valves.
6. Remove valve (5).

7. Use Tooling (B) to remove valve stem seal (4).
8. Repeat Steps 3 through 7 in order to remove the
remaining inlet and exhaust valves.
Table 10
Required Tools
Tool
Part Number
21825663
Valve Spring
Compressor
27610261
Seal Installer
27610262
Valve Guide Driver
Part Description
Qty
Illustration 49
g01333472
Typical example
KENR6241
27
2. Use Tooling (C) to install new valve stem seals (4)

onto each of the valve guides.
Illustration 51
Illustration 50
g01333471
Typical example
3. Lubricate the stem of valve (5) with clean engine

oil. Install valve (5) in the appropriate position in
the cylinder head. Check the depth of the valve
below the face of the cylinder head. Refer to
Systems Operation, Testing and Adjusting, Valve
Depth - Inspect for more information.
4. Install valve spring (3) to the cylinder head.
Position valve spring retainer (2) onto valve spring
(3).

NOTICE
g01333469
Typical example
5. Use Tooling (A) in order to compress valve spring

(3). Install valve keepers (1).
Note: Do not compress the spring so that valve
spring retainer (2) touches valve stem seal (4).
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
6. Remove Tooling (A).
7. Repeat Steps 3 to 6 for the remaining valves.
8. Place the cylinder head on a suitable support.
Ensure that the heads of the valves are not
obstructed. Gently strike the top of the valves
with a soft hammer in order to ensure that valve
keepers (1) are properly installed.
End By:
a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head Install.
28
KENR6241
i02748546
Engine Oil Filter Base Remove and Install
1. Use Tooling (A) to remove engine oil filter (6)

from engine oil filter base (5). Refer to Operation
and Maintenance Manual, Engine Oil and Filter
- Change.
2. Mark the orientation of engine oil filter base (5) for
installation. Remove bolt (2).
Removal Procedure
Note: The engine oil filter base can be oriented in

different positions.
Table 11
Required Tools
Tool
Part Number
Part Description
Strap Wrench
Qty
3. Remove bolt (4) and remove engine oil filter base

(5) from the cylinder block. Plug the oil galleries in
the cylinder block with suitable plugs.
4. Remove O-ring seal (1) from engine oil filter base

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

component life.
NOTICE
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
mandates.
Illustration 53
g01333853
Typical example
1. Ensure that the engine oil filter base is clean and

free from damage. Clean the mating surfaces of
the cylinder block.
2. Install a new O-ring seal (1) to engine oil filter
base (5). Install a new O-ring seal (3) to bolt (4).
3. Position engine oil filter base (5) against the
cylinder block. Install bolt (4) finger tight.
Illustration 52
Typical example
g01333853
4. Ensure the correct orientation of engine oil filter

base (5). Install bolt (2) finger tight.
Note: The engine oil filter base can be oriented in
different positions.
KENR6241
29

Tighten bolt (2) to a torque of 11 Nm (97 lb in).
6. Install a new engine oil filter (6). Refer to Operation
and Maintenance Manual, Engine Oil and Filter Change for the correct procedure.
i02748547
Engine Oil Cooler - Remove

Removal Procedure
Start By:
- Remove.
NOTICE
component life.
NOTICE
Illustration 54
g01361343
Typical example
3. For turbocharged engines, remove crankcase

breather (2). Refer to Disassembly and Assembly,
Crankcase Breather - Remove and Install.
4. Remove dipstick tube (1).

mandates.
1. Drain the coolant from the cooling system into
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
Cooling System Coolant - Change for the correct
procedure.
2. Drain the engine lubricating oil into a suitable
container for storage or disposal. Refer to
Operation and Maintenance Manual, Engine Oil
and Filter - Change for the procedure.
30
KENR6241
i02748549
Engine Oil Cooler - Install

NOTICE
component life.
Illustration 55
g01333881
Typical example
5. Gradually loosen bolts (11). Note the position of

any brackets that are secured by the bolts.
6. Support the assembly of engine oil cooler (3).
Remove bolts (11) and remove the assembly of
engine oil cooler (3) from the cylinder block.
7. Remove joint (5).
8. Remove O-ring seals (4) from the recesses in the
cylinder block.
Illustration 56
9. If necessary, follow Steps 9.a through 9.d in order

to disassemble the engine oil cooler.
a. Remove nuts (8).
b. Remove cooler matrix (6) from cover (7).
c. Remove O-ring seals (12) and (13).
d. Remove plate (10) and joint (9) from cover (7).
g01333881
Typical example
1. If necessary, follow Steps 1.a through 1.e in order

to assemble the engine oil cooler.
a. Ensure that cooler matrix (6) is clean and free
from damage. Ensure that cover (7) is clean
and free from damage.
b. Position new O-ring seals (12) and (13) onto
cover (7).
KENR6241
31
c. Install cooler matrix (6) to cover (7).
End By:
d. Install nuts (8). Tighten the nuts to a torque of

18 Nm (13 lb ft).

and Assembly, Fuel Injection Lines - Install.
e. Install joint (9) and plate (10).
i02748550
2. Clean the mating surface of the cylinder block.

3. Install new O-ring seals (4) to the recesses in the
cylinder block.
4. Install two bolts (11) to the upper corners of the
assembly of engine oil cooler (3). Install a new
joint (5) to the assembly of engine oil cooler (3).
5. Install the assembly of engine oil cooler (3) to the
cylinder block. Install the remaining bolts (11).
Note: Ensure that any brackets that are secured by
the bolts are installed in the correct location.
6. Tighten bolts (11) evenly to a torque of 18 Nm
(13 lb ft).
Engine Oil Relief Valve Remove and Install

Removal Procedure
Table 12
Required Tools
Tool
Part
Number
Part Description
Strap Wrench
Qty
1
NOTICE
component life.
NOTICE
mandates.
Illustration 57
g01361343
Typical example
7. Install dipstick tube (1).

8. For turbocharged engines, install crankcase
breather (2). Refer to Disassembly and Assembly,
Crankcase Breather - Remove and Install.
9. Fill the cooling system to the correct level.
procedure.
10. Fill the engine oil pan to the correct level. Refer to
and Filter - Change for the correct procedure.
32
Illustration 58
KENR6241
g01334417
Illustration 59
g01334417
Typical example
Typical example
1. If necessary, use Tooling (A) in order to remove

engine oil filter (3). Refer to Operation and
Maintenance Manual, Engine Oil and Filter Change.
1. Install a new sealing washer (1) to engine oil relief

valve (2).
2. Remove engine oil relief valve (2).

3. Remove sealing washer (1).
NOTICE
component life.
2. Install engine oil relief valve (2) to the cylinder

block. Tighten the engine oil relief valve to a
3. If necessary, install a new engine oil filter (3). Refer
to Operation and Maintenance Manual, Engine
Oil and Filter - Change for the correct procedure.
i02748551
Engine Oil Bypass Valve Remove and Install

Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
NOTICE
component life.
KENR6241
33
NOTICE
mandates.
1. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly,
Balancer - Remove.
Illustration 61
g01334433
Typical example
2. Install a new sealing washer (2) to engine oil

bypass valve (1).
3. Install engine oil bypass valve (1) to the cylinder
block. Tighten the engine oil bypass valve to a
4. If the engine is equipped with a balancer, install
Balancer - Install.
End By:
Illustration 60
g01334433
Typical example
2. Remove engine oil bypass valve (1).
a. Install the engine oil pan. Refer to Disassembly

Install.
3. Remove sealing washer (2).
NOTICE
component life.
1. Inspect the components of the engine oil bypass
valve for wear or damage. Check the valve and
the valve seat for an abnormal contact pattern.
Check the spring for weakness or damage. If
necessary, replace the engine oil bypass valve.
i02748553
Engine Oil Pump - Remove

Removal Procedure
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove and
Install.
NOTICE
component life.
34
KENR6241
i02748554
NOTICE
mandates.
Engine Oil Pump - Install

Table 13
Required Tools
Tool
Part Number
21825617
Part Description
Dial Indicator Group
Qty
1
NOTICE
component life.
Illustration 63
Illustration 62
g01334537
g01334869
1. Ensure that bushing (8) is free from wear or

damage. Refer to Specifications, Engine Oil
Pump for more information. If necessary, replace
the bushing.
1. Remove nut (5) and washer (4).

2. Remove gear (3) from the shaft of engine oil pump
(1).
3. Remove bolts (6) and remove engine oil pump (1)
from the cylinder block.
4. Remove O-ring seal (2).
KENR6241
35
i02748555
Water Pump - Remove and

Install
Removal Procedure
Start By:
a. If the engine is equipped with a fan, remove
the fan. Refer to Disassembly and Assembly,
Fan - Remove and Install. If the engine is not
equipped with a fan, remove the V-belt. Refer to
Disassembly and Assembly, V-belts - Remove
and Install.
NOTICE
component life.
Illustration 64
g01334537
2. Ensure that engine oil pump (1) is clean and free

from wear or damage. Refer to Specifications,
Engine Oil Pump for more information. If
necessary, replace the engine oil pump.
3. Install a new O-ring seal (2) to engine oil pump
(1). Lubricate the rotors of the engine oil pump
with clean engine oil.
NOTICE
mandates.
4. Align engine oil pump (1) with dowels (7). Install

the engine oil pump to the cylinder block.

System Coolant - Change for more information.
5. Install bolts (6). Tighten the bolts to a torque of

11 Nm (97 lb in).
2. Loosen the hose clamp and disconnect the hose

(not shown) from the water pump inlet.
6. Position oil pump gear (3) onto the shaft of engine

oil pump (1). Ensure that the oil pump gear is
aligned with the flat on the shaft. Install washer (4)
and nut (5). Tighten the nut to a torque of 33 Nm
(24 lb ft).
7. Use Tooling (A) to check the backlash between
oil pump gear (3) and the idler gear. Ensure that
the backlash is within specified values. Refer to
Specifications, Gear Group (Front) for further
information.
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Remove and Install.
36
KENR6241
1. Ensure that the mating surfaces of the water pump

and the cylinder block are clean and free from
damage. If the cover was removed, ensure that
the mating surfaces of the cover are clean and
free from damage.
Illustration 67
Illustration 65
g01335213
Illustration 66
g01335205
g01335205
2. If necessary, align a new joint (6) and cover (7)

with the holes in water pump (2). Install bolts (5).
Tighten the bolts to a torque of 10 Nm (89 lb in).
3. Loosen the hose clamp and disconnect hose (1)

from water pump (2).
4. Remove bolts (4) and remove water pump (2). Do
not remove bolts (5) at this time.
Note: If necessary, gently tap the water pump with a
soft faced hammer in order to loosen the water pump.
Illustration 68
g01335213
6. If necessary, remove bolts (5), and remove cover

(7). Remove joint (6).
3. Place water pump (2) in position and install bolts

(4). Ensure that bolts of different lengths are
installed in the correct positions. Tighten bolts (4)
4. Connect hose (1) and tighten the hose clamp.
NOTICE
5. Connect the hose (not shown) to the water pump

inlet and tighten the hose clamp.

component life.
KENR6241
37

procedure.
End By:
a. If the engine is equipped with a fan, install the
fan. Refer to Disassembly and Assembly, Fan Remove and Install. If the engine is not equipped
with a fan, install the V-belt. Refer to Disassembly
and Assembly, V-belts - Remove and Install.
i02748556
Water Temperature Regulator

Housing - Remove and Install
Removal Procedure
NOTICE
component life.
Illustration 69
g01335249
Typical example
NOTICE
mandates.
procedure.
2. Remove bolts (1) and remove outlet connection

(2).
3. Remove joint (3) and remove water temperature
regulator (4). Note the orientation of the water
temperature regulator for installation.
from water temperature regulator housing (6).
5. Remove bolts (7) and remove water temperature
regulator housing (6) from the cylinder head.
NOTICE
component life.
1. Inspect the water temperature regulator for
wear, damage and correct operation. Refer
to Systems Operation,Testing and Adjusting,
Water Temperature Regulator - Test for more
information. If necessary, replace the water
temperature regulator.
38
KENR6241
2. Ensure that the mating surfaces of the outlet

connection, the water temperature regulator
housing and the cylinder head are clean and free
from damage.
5. Install water temperature regulator (4) to water

temperature regulator housing (6). Ensure the
correct orientation of the water temperature
regulator.
6. Position a new joint (3) and outlet connection (2)
onto water temperature regulator housing (6).
7. Install bolts (1). Tighten the bolts to 18 Nm
(13 lb ft).
8. Connect hose (8) to water temperature regulator
housing (6). Tighten the hose clamps securely.
9. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
Manual, Cooling System Coolant -Change for
the correct procedure.
i02748557
Flywheel - Remove
Removal Procedure
Table 14
Required Tools
Illustration 70
Tool
Part Number
g01335249
Typical example
Part Description
Guide Stud
(M12 x 1.25 by 100
mm)
Qty
2
3. Position bolts (7) and a new joint (5) onto water

temperature regulator housing (6).
Start By:
4. Position water temperature regulator housing

(6) onto the cylinder head. Tighten bolts (7) to a
a. Remove the starting motor. Refer to Disassembly

and Assembly, Electric Starting Motor - Remove
and Install.
NOTICE
component life.
Illustration 71
g01335282
Orientation of the water temperature regulator
KENR6241
39
i02748558
Flywheel - Install
Table 15
Required Tools
Illustration 72
Tool
Part Number
g01335288
Part Description
Guide Stud
(M12 x 1.25 by 100
mm)
Qty
2
Typical example
1. Make a temporary mark in order to show the

orientation of the flywheel on the crankshaft.
2. Install a suitable lifting device to flywheel (2). The
weight of the flywheel is approximately 23 kg
(50 lb).
3. Remove two bolts (1) from Positions (X) on the
flywheel.
4. Install Tooling (A) in positions (X) on the flywheel.
NOTICE
component life.
Always wear protective gloves when handling

parts that have been heated.
5. Remove the remaining bolts (1) and remove

flywheel (2).
Illustration 74
g01369129
Typical example
Illustration 73
g01360927
Typical example
1. If the ring gear was removed, follow Steps 1.a

through 1.c in order to install ring gear (3) to
flywheel (2).
6. Inspect ring gear (3) and flywheel (2) for wear or

damage. If the ring gear or the flywheel is worn or
damaged, use new parts for replacement.
a. Identify the orientation of the new ring gear in

order to install the ring gear correctly onto the
flywheel.
7. To remove ring gear (3) from flywheel (2), place

the flywheel on a suitable support. Use a hammer
and a punch in order to remove the ring gear from
the flywheel.
Note: The chamfered side of gear teeth (Y) must

face toward the starting motor when the flywheel is
installed. This will ensure the correct engagement of
the starting motor.
b. Heat ring gear (3) in an oven to a maximum
temperature of 150C (302F) prior to
installation.
40
KENR6241
Note: Do not use a torch to heat the ring gear.

c. Ensure that the orientation of ring gear (3) is
correct and quickly install the ring gear onto
flywheel (2).
End By:
a. Install the starting motor. Refer to Disassembly
and Assembly, Electric Starting Motor - Remove
and Install.
i02748559
Crankshaft Rear Seal - Remove

and Install
Removal Procedure
Table 16
Required Tools
Illustration 75
g01335288
Typical example
2. Thoroughly clean the flywheel housing. Inspect

the crankshaft rear seal for leaks. If there are any
oil leaks replace the crankshaft rear seal. Refer
to Disassembly and Assembly, Crankshaft Rear
Seal - Remove and Install.
3. Ensure that the dowels are installed to the
crankshaft. Install Tooling (A) to positions (X) in
the crankshaft.
4. Install a suitable lifting device to flywheel (2). The
weight of the flywheel is approximately 23 kg
(50 lb).
5. Align flywheel (2) with Tooling (A). Install the
flywheel to the crankshaft.
Note: Ensure the correct orientation of the flywheel
on the crankshaft.
Tool
Part Number
27610311
Part Description
Qty
Drill Bit (4.10 mm)
Slide Hammer Puller
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
mandates.
NOTICE
7. Remove Tooling (A) and install the two remaining

bolts (1).

component life.
8. Remove the lifting device from the flywheel.

9. Use a suitable tool to prevent flywheel (2) from
rotating. Tighten bolts (1) to a torque of 83 Nm
(61 lb ft).
10. Check the concentricity of the flywheel. Refer
Flywheel - Inspect.
KENR6241
41
1. Ensure that the flange of the crankshaft and the

inside of the flywheel housing are clean and free
of damage. It is possible to reclaim a crankshaft
flange that has a worn seal surface, or a damaged
seal surface by installing a wear sleeve. Refer to
Disassembly and Assembly, Crankshaft Wear
Sleeve (Rear) - Remove and Install for more
information.
g01335312
Illustration 76
Typical example
1. Use Tooling (A) to drill three evenly spaced holes

in crankshaft rear seal (2).
2. Use Tooling (B) to carefully remove crankshaft
rear seal (2) from flywheel housing (1). Alternate
the position of Tooling (B) from one hole to another
hole. This will allow you to evenly remove the
crankshaft rear seal from the flywheel housing.
Illustration 77
g01335312
Typical example
Table 17
Required Tools
Tool
Part Number
Part Description
Qty
27610266
Oil Seal Installer
27610345
Oil Seal Locator
27610346
Bolt
28710476
Hard Washer
27610347
Bolt
(M12 x 1.25 by 20
mm)
Illustration 78
g01368204
Sectional view of the crankshaft rear seal, the crankshaft and the
installation tool
NOTICE
2. Apply a thin coat of clean engine oil to the lip of

crankshaft rear seal (2).

component life.
3. Use Tooling (C) in order to install crankshaft rear

seal (2), as follows:
a. Align the locator with the dowels in crankshaft
(3). Install the locator to the crankshaft. Ensure
the correct orientation of the locator.
Note: Check that the installer will slide freely over
the locator.
42
KENR6241
b. Carefully slide crankshaft rear seal (2) over the

locator until the crankshaft rear seal contacts
the rear of crankshaft (3).
Note: Ensure that the lip of the crankshaft rear seal
that is spring loaded is facing toward the flywheel
housing.
Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves
are not original equipment. The wear sleeve is
supplied with a crankshaft rear seal that has a larger
internal diameter than a standard crankshaft rear
seal. A standard crankshaft rear seal cannot be used
if a wear sleeve is installed.
c. Assemble the installer to the locator and install

the bolt and the washer. Ensure that the face
of the installer with the deep counterbore is
toward crankshaft rear seal (2).
d. Tighten the bolt until the installer bottoms out
on the locator in order to pull crankshaft rear
seal (2) into flywheel housing (1).
e. Remove Tooling (C).
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, Flywheel - Install.
i02748560
Crankshaft Wear Sleeve (Rear)

- Remove and Install
g01384938
Illustration 79
1. Use Tooling (A) in order to remove crankshaft

wear sleeve (1) from crankshaft (2).
Table 19
Required Tools
Tool
Removal Procedure
Table 18
Required Tools
Tool
Part
Number
Part Description
Puller
Qty
1
Start By:
a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
NOTICE
component life.
Part Number
Part Description
Qty
27610266
Oil Seal Installer
27610345
Oil Seal Locator
27610346
Bolt
28710476
Hard Washer
27610266
Bolt
(M12 x 1.25 by 20
mm)
NOTICE
component life.
Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
are not original equipment. The wear sleeve is
supplied with a crankshaft rear seal that has a larger
internal diameter than a standard crankshaft rear
seal. A standard crankshaft rear seal cannot be used
if a wear sleeve is installed.
1. Ensure that the crankshaft is thoroughly clean and
dry. Remove any areas of raised damage.
KENR6241
43
2. Lubricate the inner surface of the crankshaft wear

sleeve with clean engine oil.
i02748561
Flywheel Housing - Remove

and Install
Removal Procedure
Table 20
Required Tools
Illustration 80
g01377790
Tool
Part
Number
Sectional view of the crankshaft, the wear sleeve and the

installation tool
3. Use Tooling (A) in order to install the crankshaft

wear sleeve, as follows:
a. Align the locator with the dowels in crankshaft
(2). Install the locator to the crankshaft. Ensure
the correct orientation of the locator.
Note: Check that the installer will slide freely over
the locator.
b. Carefully slide crankshaft wear sleeve (3) over
the locator until the crankshaft wear sleeve
contacts the rear of crankshaft (2).
c. Assemble the installer to the locator and install
the bolt and the washer. Ensure that the face
of the installer with the deep counterbore is
toward crankshaft wear sleeve (3).
Part Description
Guide Stud
(M10 x 1.25 by 100
mm)
Qty
2
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
component life.
NOTICE
d. Tighten the bolt until the installer bottoms out

on the locator in order to pull crankshaft wear
sleeve (3) onto crankshaft (2).

mandates.
e. Remove Tooling (A).
1. Support the engine.
End By:
a. Install the new crankshaft rear seal that was
supplied with the crankshaft wear sleeve. Refer
to Disassembly and Assembly, Crankshaft Rear
44
KENR6241

8. Remove crankshaft rear seal (4) from flywheel
housing (2).
Table 21
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
(M10 x 1.25 by100
mm)
21825617
NOTICE
Illustration 81
g01335374
Typical example

component life.
1. Ensure that the mating surfaces of the cylinder
block and the flywheel housing are clean and free
from damage.
Illustration 82
g01366220
Typical example
2. Remove two bolts (5) from positions (X) on

flywheel housing (2).
3. Install Tooling (A) to positions (X) on flywheel
housing (2).
4. Attach a suitable lifting device to flywheel
housing (2). The weight of the flywheel housing is
approximately 32 kg (71 lb).
5. Remove the remaining bolts (5).
6. Carefully remove flywheel housing (2) from dowels
(3) and from the cylinder block.
Illustration 83
g01335383
Typical example
2. Inspect dowels (3) in the cylinder block. If

necessary, replace the dowels.
Note: If necessary, tap the flywheel housing with a

soft faced hammer in order to separate the flywheel
housing from the cylinder block.
KENR6241
45
i02748562
Crankshaft Pulley - Remove

and Install
Removal Procedure
Table 22
Required Tools
Illustration 84
g01335381
Tool
Part Number
27610267
Part Description
Qty
Socket
Puller Group
3. Install Tooling (A) to the cylinder block.

4. Install a new joint (1) to the cylinder block.
5. Install a suitable lifting device to flywheel housing
(2). The weight of the flywheel housing is
6. Use the lifting device to align flywheel housing (2)
with Tooling (A). Install the flywheel housing to the
cylinder block.
Start By:
a. Remove the V-belt. Refer to Disassembly and
Assembly, V-belts - Remove and Install.
NOTICE
component life.

8. Remove Tooling (A). Install the remaining bolts (5).
1. Use a suitable method to prevent the crankshaft

from rotating.

10. Remove the lifting device.
11. Use Tooling (B) to check the alignment of the
flywheel housing with the crankshaft. Refer
Flywheel Housing - Inspect.
12. Install a new crankshaft rear seal (4). Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Install.
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, Flywheel - Install.
Illustration 85
g01335388
Typical example
46
KENR6241
g01335508
Illustration 86
Typical example
2. Use Tooling (A) in order to loosen nut (3).

3. Install Tooling (B) to crankshaft pulley (2). Use
Tooling (B) to loosen the crankshaft pulley.
Remove Tooling (B).
4. Remove nut (3) and remove crankshaft pulley (2).
g01368691
5. If necessary, remove woodruff key (1) from

crankshaft (4).
Illustration 87
1. Ensure that the threads of crankshaft (4) and nut

(3) are clean and free from damage. If necessary,
install woodruff key (1) to the crankshaft.
Typical example
Table 23
Required Tools
Tool
C
Part Number
1861108
Part Description
POWERPART
Silicon RTV Sealing
and Jointing
Compound
Qty
1
NOTICE
component life.
2. Apply a continuous bead of Tooling (C) around

the threads of crankshaft (4) at position (X)
approximately 10 mm (0.4 inch) from the shoulder
of the crankshaft.
3. Install pulley (2) to crankshaft (4).
4. Use a suitable method to prevent the crankshaft
from rotating.
5. Install nut (3). Tighten the nut to a torque of
490 Nm (361 lb ft).
End By:
a. Install the V-belt. Refer to Disassembly and
Assembly, V-belts - Remove and Install.
KENR6241
47
i02748563
Crankshaft Front Seal Remove and Install
Table 25
Required Tools
Tool
Part
Number
Removal Procedure
C
Table 24
27610268
Required Tools
Tool
Part Number
27610311
Part Description
Part Description
Qty
Seal Installer Stud
Washer
Seal Installer Sleeve
Qty
Drill Bit (4.10 mm)
Slide Hammer Puller
NOTICE
component life.
Start By:
a. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
NOTICE
component life.
NOTICE
Ensure that the main lip is used in order to remove the
crankshaft front seal. Do not damage the edge of the
housing for the crankshaft front seal.
Illustration 89
g01335757
Typical example
1. Ensure that the bore in front housing (1) and the

nose of the crankshaft are clean and free from
damage.
2. Lubricate the outside diameter of a new crankshaft
front seal (2) with clean engine oil.
3. Position crankshaft front seal (2) in the bore of
front housing (1).
Illustration 88
g01335759
Typical example
1. Use Tooling (A) to drill three evenly spaced holes

in crankshaft front seal (2).
2. Use Tooling (B) to carefully remove crankshaft
front seal (2). Alternate the position of Tooling (B)
from one hole to another hole. This will allow you
to evenly remove the crankshaft front seal from
front housing (1).
NOTICE
Ensure that the lip of the crankshaft front seal that is
spring loaded is facing toward the inside of the front
housing and that it is square with the bore of the housing for the crankshaft front seal.
4. Use Tooling (C) to install crankshaft front seal (2)
into front housing (1).
5. Remove Tooling (C) and check for correct
installation of crankshaft front seal (2).
6. Apply clean engine oil to the lip of crankshaft front
seal (2).
48
KENR6241
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, Crankshaft Pulley - Remove and
Install.
i02748564
Front Cover - Remove and

Install
Removal Procedure
NOTICE
component life.
g01335768
Illustration 91
Typical example
1. Ensure that the mating surface of front housing (1)

and plate (2) are clean and free from damage.
3. Position plate (2) onto front housing (1).
4. Install bolts (4) and tighten to 18 Nm (13 lb ft).
i02748565
Idler Gear - Remove and Install

Removal Procedure
Table 26
Illustration 90
g01335768
Required Tools
Typical example
Tool
Part
Number
27610269
Part Description
Idler Shaft Puller
Qty
1

NOTICE
component life.
Start By:
Install.
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
KENR6241
49
NOTICE
component life.
NOTICE
mandates.
g01337783
Illustration 93
Typical example
4. Remove bolt (2), washer (3), and plate (4).

5. Remove idler gear (5) from shaft (1).
Illustration 92
g01337345
Alignment of timing marks
2. Ensure that timing marks (X) on the gears are

aligned. Refer to Illustration 92.
g01337810
Illustration 94
Extracting the shaft from the cylinder block
Alternatively, make temporary timing marks on the

gears in order to show alignment.
3. Loosen the nuts on all rocker arms. Unscrew the
adjusters on all rocker arms until all valves are
fully closed.
Note: Failure to ensure that ALL adjusters are fully
unscrewed can result in contact between the valves
and pistons.
6. If necessary, follow Steps 6.a and 6.b in order to

remove shaft (1).
a. Make a temporary mark on the cylinder block
in order to show the position of oil hole (Y).
b. Use Tooling (A) to extract shaft (1) from the
cylinder block.
Table 27
Required Tools
Tool
Part Number
Part Description
Qty
21825617
50
KENR6241
NOTICE
component life.
Illustration 96
g01337345
Alignment of timing marks
4. Lubricate shaft (1) with clean engine oil. Position

idler gear (5) onto shaft (1). Ensure that timing
marks (X) on the gears are aligned. Refer to
Illustration 96.
5. Lubricate the bearing surface of plate (4) with
clean engine oil. Install plate (4), washer (3), and
bolt (2).
Illustration 95
g01364486
Typical example
1. If necessary, follow Steps 1.a and 1.b in order to

install shaft (1).
a. Align oil hole (Y) on shaft (1) with the temporary
mark on the cylinder block.
b. Use a soft faced hammer and a hard wooden
drift to install shaft (1) into the cylinder block.
Note: Install shaft (1) squarely into the cylinder block.
Ensure that oil hole (Y) is aligned with the temporary
mark and that the shoulder on the shaft is seated
against the face of the cylinder block.
2. Ensure that plate (4) and idler gear (5) are clean
and free from wear or damage. If necessary,
replace any components that are worn or
damaged.
Note: Ensure that the bearing surface of the plate

is toward the idler gear.
7. Use a feeler gauge in order to check the end play
of idler gear (2). Refer to Specifications, Gear
Group (Front) for more information.
8. Use Tooling (B) in order to inspect the backlash
of the gear group. Refer to Systems Operation,
Testing and Adjusting, Gear Group - Inspect.
9. Lightly lubricate all of the gears with clean engine
oil.
10. Install the front housing. Refer to Disassembly
Install.
11. Adjust the engine valve lash. Refer to Systems
Operation, Testing and Adjusting, Engine Valve
Lash - Inspect/Adjust.
End By:
a. Install the valve mechanism cover. Refer to
KENR6241
51
i02748567
Housing (Front) - Remove and

Install
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
b. Remove the alternator. Refer to Disassembly and
Assembly, Alternator - Remove and Install.
c. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
d. Remove the front cover. Refer to Disassembly and
Assembly, Front Cover - Remove and Install.
Illustration 97
e. Remove the engine oil pan. Refer to Disassembly

Install.
NOTICE
component life.
NOTICE
g01349330
Typical example
2. Remove front housing (4) from plate (6).

Note: Avoid damage to crankshaft front seal (3)
when the front housing is removed.
Note: It is not necessary to remove dowels (1).
NOTICE
component life.

mandates.
52
KENR6241
d. Install the alternator. Refer to Disassembly and

Assembly, Alternator - Remove and Install.
e. Install the fan. Refer to Disassembly and
Assembly, Fan - Remove and Install.
i02748568
Front Plate - Remove

Removal Procedure
Start By:
a. Remove the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Remove.
Illustration 98
g01349330
Typical example
1. Ensure that front housing (4) and the nose of the

crankshaft are clean and free from damage. Clean
the mating surface of plate (6).
2. Inspect crankshaft front seal (3) for wear or
damage. If necessary, replace the crankshaft
front seal. Refer to Disassembly and Assembly,
Crankshaft Front Seal - Remove and Install.
Apply clean engine oil to the lip of the crankshaft
front seal.
b. Remove the idler gear. Refer to Disassembly and

Assembly, Idler Gear - Remove and Install.
c. Remove the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove and Install.
NOTICE
component life.
3. Install a new joint (5) to plate (6). Ensure that the

joint is correctly seated on dowels (1).
4. Align front housing (4) with dowels (1). Install the
front housing to plate (6).
Note: Ensure that the crankshaft front seal is not
damaged when the front housing is installed.
18 Nm (13 lb ft).
End By:
Illustration 99

Install.
1. Remove nut (3) and washer (2).
b. Install the front cover. Refer to Disassembly and

Assembly, Front Cover - Remove and Install.
g01365310
2. Remove gear (1) from the shaft of engine oil pump

(4).
c. Install the crankshaft pulley. Refer to Disassembly

and Assembly, Crankshaft Pulley - Remove and
Install.
KENR6241
Illustration 100
53
g01365307
Illustration 101
g01365307
Typical example
Typical example
1. Ensure that plate (7) and the mating surface of the

cylinder block are clean and free from damage.
Ensure that dowels (6) are located in the cylinder
block.
4. Remove plate (7) from the cylinder block.

Note: It is not necessary to remove dowels (6).
6. If necessary, remove the bracket for the alternator
(not shown) from plate (7).
i02748569
2. Install a new joint (8) to the cylinder block.

3. Align plate (7) with dowels (6) and install the plate
to the cylinder block.
12 Nm (106 lb in).
Front Plate - Install

NOTICE
component life.
Illustration 102
g01365310
5. Position gear (1) onto the shaft of engine oil pump

(4). Ensure that the gear is aligned with the flat on
the shaft. Install washer (2) and nut (3). Tighten
the nut to a torque of 33 Nm (24 lb ft).
6. If necessary, Install the bracket for the alternator
(not shown) to plate (7).
54
KENR6241
End By:
a. Install the camshaft. Refer to Disassembly and
b. Install the idler gear. Refer to Disassembly and
c. Install the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Install.
i02748570
Crankcase Breather - Remove

and Install
g01344989
Removal Procedure
Illustration 103
NOTICE

from crankcase breather (1).

component life.

from crankcase breather (1).
Typical example
3. Remove bolts (2) and remove crankcase breather

(1).
NOTICE
NOTICE

mandates.

component life.
KENR6241
Illustration 104
55
g01344989
Illustration 105
g01336694
Typical example
Typical example
1. Connect hose (4) to crankcase breather (1) and

tighten the hose clamp.
1. If the engine is equipped with a turbocharger,

follow Steps 1.a through 1.c in order to remove
the air pipe.
2. Position crankcase breather (1) and install bolts

(2). Tighten the bolts to a torque of 18 Nm
(13 lb ft).
3. Connect hose (3) to crankcase breather (1) and
tighten the hose clamp.
i02748571
a. Loosen hose clamps (6) and remove hose (4).

b. Remove bolts (5) and remove air pipe (3) from
turbocharger (1). Remove gasket (2).
c. Plug the opening in the inlet manifold and the
opening in the turbocharger with suitable plugs.
Valve Mechanism Cover Remove and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
Illustration 106
g01345049

from valve mechanism cover (8).
56
KENR6241
3. Remove bolts (7). Remove valve mechanism

cover (8) from the cylinder head.
4. Remove seal (9) from valve mechanism cover (8).
NOTICE
component life.
1. Thoroughly clean the valve mechanism cover.
Clean the mating surfaces of the cylinder head.
Illustration 108
g01336694
Typical example
6. If the engine is equipped with a turbocharger,

follow Steps 6.a through 6.c in order to install the
air pipe.
a. Remove the plugs from the inlet manifold and
from the turbocharger.
b. Position a new joint (2) and air pipe (3) onto
turbocharger (1). Install bolts (5). Tighten the
bolts to a torque of 18 Nm (13 lb ft).
c. Install hose (4) and tighten hose clamps (6)
securely.
Illustration 107
g01345049
2. Install a new seal (9) to valve mechanism cover

(8).
Note: Ensure that the joint is fully seated into the
groove of the valve mechanism cover.
3. Place valve mechanism cover (8) in position on
the cylinder head.
12 Nm (106 lb in).
5. Connect hose (10) to valve mechanism cover (8)
and tighten the hose clamp.
i02748572
Rocker Shaft and Pushrod Remove

Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to
NOTICE
component life.
KENR6241
57
i02748573
Rocker Shaft - Disassemble

Disassembly Procedure
Table 28
Required Tools
Tool
Part
Number
Part Description
Retaining Ring Pliers
Qty
1
Start By:
a. Remove the rocker shaft and pushrods. Refer to
Pushrod - Remove.
Illustration 109
g01345395
Typical example
1. Loosen the nuts and adjustment screws (1) on all

rocker arms.

3. Progressively loosen bolts (3). Begin at the ends

of the rocker shaft assembly and work toward the
center.

Note: Damage to the rocker shaft may occur if the

long bolts are loosened first. To avoid distortion
of the rocker shaft assembly, each bolt should be
loosened by a quarter of a turn at one time. Repeat
the procedure until all bolts are loosened.
NOTICE
component life.

5. Remove rocker shaft assembly (2) from the
cylinder head.
6. Place temporary identification marks on pushrods
(4) and pads (6).
Note: Identification will ensure that the pushrods and
pads can be reinstalled in the correct position. Do not
interchange the positions of used pushrods or pads.
7. Remove pushrods (4) from the cylinder head.
Remove pads (6) from the valve stems.
58
KENR6241
i02748575
Rocker Shaft - Assemble

Assembly Procedure
Table 29
Required Tools
Tool
Part
Number
Part Description
Qty
1
1. Ensure that all components are clean and free

Rocker Shaft for more information. If necessary,
replace any components that are worn or
damaged.
Note: Ensure that all oil holes are free from
blockages.
2. Lubricate all of the components with clean engine
oil before assembly.
Illustration 110
g01345402
1. Make an identification mark on each rocker arm

assembly in order to show the location. Note the
mark at position (X) for installation purposes.
Note: The components must be reinstalled in the
original location. Do not interchange components.
2. Use Tooling (A) to remove retaining rings (8).
3. Remove rocker arm assembly (5).
4. Remove pedestal (6) from rocker shaft (3).
5. Remove rocker arm assembly (7).
6. Remove spring (4).
remaining rocker arm assemblies from rocker
shaft (3).
8. If necessary, remove nuts (1) and adjusters
(2) from the rocker arms. Make a temporary
identification mark on each adjuster in order to
show the location.
Illustration 111
Note: The components must be reinstalled in the

original location. Do not interchange components.
g01345402
3. If necessary, install nuts (1) and adjusters (2) to

rocker arm assemblies (5) and (7). If the original
adjusters are reused, ensure that the adjusters
are installed in the original positions.
KENR6241
59
4. Use Tooling (A) to install retaining ring (8) to the

front end of rocker shaft (3). The front end of the
rockershaft is identified by the mark at Position
(X). Ensure that the mark at position (X) is upward.
5. Install rocker arm assembly (5) to rocker shaft (3).
6. Install bracket (6) to rocker shaft (3).
Note: Ensure correct orientation of the bracket. Refer
to Illustration 111.
7. Install rocker arm assembly (7) to rocker shaft (3).
Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.
Illustration 112
g01345395
Typical example
8. Install spring (4) to rocker shaft (3).

9. Repeat Steps 5 through 8 in order to assemble
the remaining components of the rocker shaft
assembly.
10. Use Tooling (A) to install retaining ring (8) to the
rear end of rocker shaft (3).
2. Apply clean engine lubricating oil to both ends of

pushrods (4). Install the pushrods to the engine
with the cup upward. Ensure that the pushrods are
installed correctly in the socket of the valve lifters.
Note: If the pushrods have been used, ensure that
the pushrods are installed in original positions.
End By:
3. Lubricate the top of the valve stems with clean

engine oil. Install caps (6) to the valve stems.
a. Install the rocker shaft and pushrods. Refer to

Pushrod - Install.
Note: If the caps have been used, ensure that the

caps are installed in original positions.
4. Install rocker shaft (2) to the cylinder head.
i02748576
Rocker Shaft and Pushrod Install
Note: Ensure that the ends of adjustment screws (1)

are correctly seated in ends of pushrods (4). Also
ensure that valve caps (6) are in position under the
rocker arms.
5. Install bolts (3) to the rocker shaft. Tighten the

bolts to a torque of 15 Nm (11 lb ft). Begin at
the center of the rocker shaft assembly and work
outward.
NOTICE
component life.
Rocker Shaft for more information. Replace any
Note: Damage to the rockershaft may occur if the

short bolts are tightened first.
6. Install bolts (5) to the rocker shaft. Tighten the
bolts to a torque of 15 Nm (11 lb ft).
7. Adjust the valve lash. Refer to Systems Operation,
Testing and Adjusting, Engine Valve Lash Inspect/Adjust for the correct procedure.
60
KENR6241
End By:
a. Install the valve mechanism cover. Refer to

procedure.
i02748577
Cylinder Head - Remove

Removal Procedure
Table 30
Required Tools
Tool
Part Number
Part Description
Lifting Bracket
Qty
2
Start By:
a. Remove the exhaust manifold. Refer to
Disassembly and Assembly, Exhaust Manifold
Illustration 113
b. Remove the fuel injectors. Refer to Disassembly

and Assembly, Fuel Injectors - Remove and
Install.
c. Remove the glow plugs. Refer to Disassembly
and Assembly, Glow Plugs - Remove and Install.
d. Remove the rocker shaft and pushrods. Refer to
Pushrod - Remove.
g01362487
Typical example
2. Disconnect hose (2) from water temperature

regulator housing (1).
3. Remove breather hose (4).
4. If necessary, remove inlet manifold (3). Refer
to Disassembly and Assembly, Inlet Manifold Remove and Install.
NOTICE
component life.
NOTICE
Illustration 114

mandates.
g01001090
The cylinder head tightening sequence
KENR6241
61
Illustration 116
g01352734
9. Note the position of dowels (8) in the cylinder

block. Do not remove the dowels unless the
dowels are damaged.
Illustration 115
g01346253
5. Gradually loosen cylinder head bolts (5) in reverse

numerical order to the sequence that is shown in
Illustration 114. This will prevent distortion of the
cylinder head.
6. Remove cylinder head bolts (5) from cylinder head
(6).
7. Attach Tooling (A) and a suitable lifting device to
cylinder head (6). Carefully lift the cylinder head
off the cylinder block. The weight of the cylinder
head is approximately 34 kg (75 lb).
Note: Do not use a lever to separate the cylinder
head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head
during the removal procedure. Avoid contamination
of the cylinder bores with coolant or with debris.
Illustration 117
g01346658
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
Typical example
8. Remove gasket (7).
11. If necessary, remove water temperature regulator

housing (1). Refer to Disassembly and Assembly,
Water Temperature Regulator Housing - Remove
and Install.
10. If necessary, remove bolts (11) and remove lifting

bracket (10). Remove joint (9).
62
KENR6241
i02748578
Cylinder Head - Install

Table 31
Required Tools
Tool
Part Number
Part Description
Qty
Lifting Bracket
Guide Stud
(M12 x 1.75 by 100
mm)
Straight Edge
NOTICE
Illustration 119

component life.
1. Thoroughly clean the mating surfaces of the
cylinder head and the cylinder block. Ensure that
there is no debris in the cylinder bores, the coolant
passages or the lubricant passages.
g01346658
Typical example
5. If necessary, install a new joint (9), lifting bracket

(10) and bolts (11) to cylinder head (6). Tighten
the bolts to a torque of 11 Nm (97 lb in).
2. Inspect the mating surface of the cylinder head for

distortion. Refer to Specifications, Cylinder Head
for more information.
Illustration 118
g01352861
3. Inspect dowels (8) for damage. If necessary,

replace the dowels in the cylinder block.
4. Install Tooling (B) to the cylinder block. Refer to
Illustration 118.
Illustration 120
g01346253
6. Align cylinder head gasket (7) with Tooling (B) and

install the cylinder head gasket onto the cylinder
block.
Note: Ensure that the word UP on the cylinder head
gasket is upward.
KENR6241
63
7. Use Tooling (A) and a suitable lifting device to lift

cylinder head (6). The weight of the cylinder head
is approximately 34 kg (75 lb). Align cylinder head
(6) with Tooling (B) and install the cylinder head to
the cylinder block.
Note: Ensure that the cylinder head is correctly
seated on dowels (8).
8. Remove Tooling (B).
Illustration 123
g01362487
Typical example
Illustration 121
g01346700
9. Clean cylinder head bolts (5). Inspect the threads

of the bolts. Use Tooling (C) in order to check the
bolts. The bolts must be renewed if there is any
visual reduction in the diameter over area (X).
10. Lubricate the threads and the shoulder of cylinder
head bolts (5) with clean engine oil before
installation.
11. Install cylinder head bolts (5) to cylinder head (6).
13. If necessary, install water temperature regulator

housing (1). Refer to Disassembly and Assembly,
Water Temperature Regulator Housing - Remove
and Install.
14. Connect hose (2) to water temperature regulator
housing (1).
15. If necessary, install inlet manifold (3). Refer to
Disassembly and Assembly, Inlet Manifold Remove and Install.
16. Install breather hose (4).
17. Install the rocker shaft and pushrods. Refer to
Pushrod - Install.
procedure.
End By:
a. Install the glow plugs. Refer to Disassembly and
Assembly, Glow Plugs - Remove and Install.
Illustration 122
g01001090
The cylinder head tightening sequence
b. Install the fuel injectors. Refer to Disassembly and

Assembly, Fuel Injectors - Remove and Install.
12. Tighten cylinder head bolts (5) in numerical order

to the sequence that is shown in Illustration 122.
Tighten the cylinder head bolts to a torque of
118 Nm (87 lb ft).
c. Install the exhaust manifold. Refer to Disassembly

and Assembly, Exhaust Manifold - Remove and
Install.
64
KENR6241
i02748579
Lifter Group - Remove and

Install
3. Repeat Steps 1 and 2 in order to remove the

remaining lifters.
Table 33
Required Tools
Removal Procedure
Table 32
Tool
Part Number
Part Description
Telescoping Magnet
Qty
1
Required Tools
Tool
Part
Number
Part Description
Telescoping Magnet
Qty
1
Start By:
a. If the engine is equipped with a balancer, remove
Balancer - Remove. If the engine is not equipped
with a balancer, remove the engine oil pan. Refer
to Disassembly and Assembly, Engine Oil Pan
b. Remove the camshaft. Refer to Disassembly and
NOTICE
component life.
NOTICE
component life.
NOTICE
It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
1. Clean the lifters. Follow Steps 1.a through 1.c in
order to inspect the lifters. Replace lifters that are
worn or damaged.
a. Inspect the seat of the pushrod in the lifter for
visual wear or damage.
b. Inspect the shank of the lifter for wear or
damage. Refer to Specifications, Lifter Group
for more information.
c. Inspect the face of the lifter that runs on the
camshaft for visual wear or damage.
2. If the crankshaft is installed, rotate the crankshaft
to access to the cylinder block in order to install
lifters (1).
3. Lubricate lifters (1) with clean engine oil.
Illustration 124
g01343537
Typical example
1. If the crankshaft is installed, rotate the crankshaft

in order to gain access to lifters (1).
2. Use Tooling (A) to remove lifters (1).
Note: Make a temporary identification mark on each
lifter in order to identify the correct location.
Illustration 125
g01343537
Typical example
KENR6241
65
4. Use Tooling (A) to install lifters (1) to the cylinder

block. Ensure that used lifters are installed in the
correct location.
Note: The lifters should be free to rotate.
5. Repeat Steps 2 through 4 in order to install the
remaining lifters.
End By:
a. Install the camshaft. Refer to Disassembly and
b. If the engine is equipped with a balancer, install
Balancer - Install. If the engine is not equipped
with a balancer, install the engine oil pan. Refer
i02748580
Camshaft - Remove and Install
g01349741
Illustration 126
Typical example
4. Ensure that gears (2) and (3) are marked in order

to show alignment. Refer to Illustration 126.
Note: Identification will ensure that the camshaft can
be installed in the original position.
Removal Procedure
Start By:
Install.
NOTICE
component life.
g01350309
Illustration 127
Typical example
1. The engine should be mounted on a suitable

stand and placed in the inverted position.
2. Rotate the crankshaft so that number one piston
is at the top center position on the compression
stroke. Refer to Systems Operation, Testing and
Adjusting, Finding Top Center Position for No.1
Piston.
3. Remove the rocker shaft and pushrods. Refer to
Pushrod - Remove.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
6. Carefully remove camshaft assembly (4) from the
cylinder block.
7. If necessary, remove the camshaft gear. Refer to
Disassembly and Assembly, Camshaft Gear.Remove and Install.
Table 34
Required Tools
Tool
Part
Number
21825617
Part Description
Qty
1
66
KENR6241

12 Nm (106 lb in).
NOTICE
component life.
1. Ensure that the camshaft assembly is clean and
free from wear or damage. If necessary, install
the camshaft gear. Refer to Disassembly and
Assembly, Camshaft Gear.- Remove and Install.
2. Lubricate the camshaft assembly with clean
engine oil prior to installation.
5. Use Tooling (A) to check the backlash between

gears (2) and (3). Ensure that the backlash for
the gears is within specified values. Refer to the
Specifications, Gear Group (Front) for further
information.
6. Use Tooling (A) to check the end play for camshaft
gear (3). Ensure that the end play is within
specified values. Refer to the Specifications,
Camshaft for further information.
7. Lubricate the teeth of the gears with clean engine
oil.
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, Housing (Front) - Remove and Install.
b. Install the rocker shaft and pushrods. Refer to
Pushrod - Install.
i02748582
Illustration 128
g01349741
Camshaft Gear - Remove and

Install
Typical example
Removal Procedure
Start By:
a. Remove the camshaft assembly from the engine.
Refer to Disassembly and Assembly, Camshaft
NOTICE
Illustration 129
g01350309

component life.
Typical example
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
3. Carefully install camshaft assembly (4) to the
cylinder block. Ensure that the timing marks on
gears (2) and (3) are in alignment and that the
mesh of the gears is correct. Refer to Illustration
128.
KENR6241
67

3. Raise the temperature of camshaft gear (1). Align
the camshaft gear with woodruff key (3) and install
the camshaft gear to camshaft (4).
End By:
Illustration 130
g01350917
1. Place the camshaft assembly on a suitable

support. Use a press to remove camshaft gear (1)
from camshaft (4).
2. Remove thrust plate (2) and woodruff key (3) from
camshaft (4). Note the orientation of the thrust
plate for installation.
a. Install the camshaft assembly to the engine.

Refer to Disassembly and Assembly, Camshaft
i02748583
Engine Oil Pan - Remove and

Install
Removal Procedure for the Engine
Oil Pan
NOTICE
NOTICE

component life.
1. Ensure that all components of the camshaft
assembly are clean and free from damage.

component life.
NOTICE
mandates.
Illustration 131
g01350917
2. Install woodruff key (3) and thrust plate (2) to

camshaft (4).
Note: Ensure that the machined face of the thrust
plate is toward the camshaft.
68
Illustration 132
KENR6241
g01347462
1. Remove oil drain plug (3). Drain the engine oil into
Illustration 133
g01347459
The oil strainer for engines without a balancer
2. Remove sealing washer (2) from oil drain plug (3).

3. Remove bolts (4) from engine oil pan (1).
4. Carefully separate engine oil pan (1) from the
cylinder block.
Note: Avoid damage to the engine oil pan during
removal.
Removal Procedure for the Oil

Strainer
NOTICE
component life.
Illustration 134
g01347461
The oil strainer for engines that are equipped with a balancer

2. Remove oil strainer (6).
3. Remove O-ring seal (5) from oil strainer (6).
KENR6241
69
Installation Procedure for the Oil

Strainer
NOTICE
Installation Procedure for the

Engine Oil Pan
Table 35

component life.
1. Clean all mating surfaces thoroughly.
Required Tools
Tool
Part Number
Part Description
Qty
21826038
POWERPART
Silicon Adhesive
21820117
POWERPART
Threadlock and
Nutlock
NOTICE
component life.
1. Ensure that the engine oil pan is clean and free
from damage. Clean the mating surface of the
cylinder block.
Illustration 135
g01347459
The oil strainer for engines without a balancer
Illustration 137
Illustration 136
g01347462
g01347461
The oil strainer for engines that are equipped with a balancer
2. Install a new O-ring seal (5) to oil strainer (6).

3. Install oil strainer (6) and install bolts (7).
70
KENR6241
NOTICE
component life.
Illustration 138
g01347865
The pattern of application of sealant to the engine oil pan.
2. Apply a continuous bead of Tooling (A) to the

mating surface of engine oil pan (1) on the inside
of the bolt holes. Refer to Illustration 138 for the
correct pattern of application. The bead of Tooling
(A) should be approximately 2 mm (0.080 inch)
in diameter.
NOTICE
mandates.
3. Ensure that bolts (4) are clean and dry. Apply

Tooling (B) to the threads of the bolts.
4. Position engine oil pan (1) onto the cylinder block
and install bolts (4).
5. Tighten bolts (4) to a torque of 11 Nm (97 lb in).
6. Install a new sealing washer (2) to oil drain plug
(3).
7. Install oil drain plug (3) to engine oil pan (1).
Tighten the oil drain plug to a torque of 39 Nm
(29 lb ft).
8. Fill the engine oil pan to the correct level. Refer to
and Filter - Change for the correct procedure.
i02748584
Balancer - Remove
Removal Procedure
Start By:
a. Remove the engine oil pan and remove the oil
strainer. Refer to Disassembly and Assembly,
Engine Oil Pan - Remove and Install.
Illustration 139
g01344508
Note: If the balancer will be disassembled, loosen

bolts (4) before the balancer is removed from the
engine.
2. Support the weight of the balancer. The balancer
weighs approximately 23 kg (51 lb). Remove bolts
(3) and remove balancer (1) from the engine.
KENR6241
71
3. Do not remove dowels (2) unless the dowels are

damaged.
i02748586
Balancer - Disassemble
Table 36
Required Tools
Tool
Part
Number
Combination Puller
27610275
Bearing Installer Group
Part Description
Qty
Illustration 141
g01344528
Illustration 142
g01344665
NOTICE
component life.
Timing marks
1. Remove bolts (4) and washers (5). Use Tooling

(A) in order to remove gears (6). Ensure that
balancer shaft (10) is protected from damage.
Note: Gears (6) have different Markings (X). Refer
to Illustration 142. Identify the position of the gears
for installation.
2. Remove keys (7). Use Tooling (B) in order to
remove retaining rings (8).
Illustration 140
g01344515
72
KENR6241
1. Ensure that all components of the balancer are

clean and free from damage.
g01344533
Illustration 143
3. Carefully tap the assembly of bearing (9) and

balancer shaft (10) forward until the shaft is clear
of bushing (11). Refer to Illustration 143.
4. Use Tooling (A) in order to remove bearing (9)
from balancer shaft (10).
Note: Ensure that the balancer shaft is protected
from damage.
5. Slide balancer shaft (10) back through bushing
(11) until the shaft is clear of the balancer.
6. If necessary, use Tooling (C) in order to remove
bushing (11) from balancer (1).
i02748588
Balancer - Assemble
Illustration 144
g01344574
2. If new bushing (11) is installed to the balancer,

follow Steps 2.a and 2.b.
a. Align oil holes (Z) in bushing (11) to drilling (Y)
in balancer (1).
b. Use Tooling (C) to install bushing (11) to
balancer (1). Ensure that the oil holes (Z) are
correctly aligned to drilling (Y).
Assembly Procedure
Table 37
Required Tools
Tool
Part
Number
C
D
Part Description
Qty
27610275
Bearing Installer Group
21820117
POWERPART
Threadlock and Nutlock
NOTICE
component life.
KENR6241
73
g01344665
Illustration 146
Timing marks
7. Align gears (6) with keys (7) and install the gears
to balancer shafts (10). Ensure that the gears are
installed in the correct position.
Illustration 145
g01344515
3. Use Tooling (C) in order to press bearings (9) into

balancer (1).
Note: Do not press on the inner race of the bearing
as this could result in damage to the bearing.
Note: The gears have different Markings (X). The

right hand gear is marked 1,1 and 2,2. The left hand
gear is marked 2. Refer to Illustration 146.
8. Apply Tooling (D) to the threads of bolts (4). Install
bolts (4) and washers (5). Tighten the bolts to a
4. Use Tooling (B) to install retaining rings (8).

Note: Ensure that the retaining rings are fully located
into the grooves in the balancer.
5. Lubricate balancer shafts (10) and bushing (11)
with clean engine oil. Carefully install the balancer
shafts to balancer (1).
6. Install keys (7).
i02748589
Balancer - Install
Table 38
Required Tools
Tool
Part Number
21825617
Part Description
Qty
1
NOTICE
component life.
74
KENR6241
g01344971
Illustration 149
Alignment of the timing marks
Illustration 147
g01344665
Timing marks
2. Align dowels (2) with the holes in the cylinder

block. Align mark 1,1 on gear (6) to mark 1 on
crankshaft gear (12). Refer to Illustration 149.
Position balancer (1) on the engine. The balancer
weighs approximately 23 kg (51 lb).
30 Nm (22 lb ft).
4. Use Tooling (F) in order to check the backlash
between gears (6). Refer to Specifications, Gear
Group (Front).
5. Use Tooling (F) in order to check the
backlash between gears (6) and (12). Refer to
Specifications, Gear Group - Front for further
information.
End By:
Install.
i02748590
Pistons and Connecting Rods

- Remove
Removal Procedure
Illustration 148
g01344983
1. Ensure that dowels (2) are seated in balancer (1).

Ensure that marks 2,2 and 2 on gears (6) are
aligned. Refer to Illustration 147.
Table 39
Required Tools
Tool
Part Number
27610274
Part Description
Ridge Reamer
Qty
1
KENR6241
75
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
b. Remove the engine oil pan and remove the oil
NOTICE
component life.
Balancer - Remove.
2. Rotate the crankshaft until the piston that is being
removed is at the bottom center position.
3. Use Tooling (A) to remove the carbon ridge from
the top inside surface of the cylinder bore.
Note: Use tape or rubber tubing on the connecting

rod bolts to protect the crankshaft journals from
damage.
7. Carefully push the piston and the connecting rod
assembly out of the cylinder bore. Lift the piston
out of the top of the cylinder block.
remaining pistons and connecting rods.
i02748591

- Disassemble
Table 40
Required Tools
Tool
Part Number
Part Description
Qty
Ring Expander
27610275
Driver Group
Start By:
a. Remove the pistons and connecting rods. Refer
to Disassembly and Assembly, Piston and
Connecting Rods - Remove.
NOTICE
component life.
Illustration 150
g01352319
4. The connecting rod and the connecting rod cap

have matching numbers (X) on the side. Note
the location of the connecting rod for installation.
If necessary, make a temporary mark on the
connecting rod and the connecting rod cap in
order to identify the cylinder number.
5. Remove nuts (2).
6. Remove connecting rod cap (1) from the
connecting rod.
Illustration 151
g01359107
Piston from a naturally aspirated engine

(X) Number
(Y) Number
76
KENR6241
2. Place the piston and connecting rod assembly on

a suitable surface with the connecting rod upward.
Use Tooling (A) in order to remove retaining rings
(4).
3. Remove piston pin (3) and connecting rod (1) from
piston (2).
Note: If the piston pin cannot be removed by hand,
heat the piston to a temperature of 45 5 C
(113 9 F). Do not use a torch to heat the piston.
Illustration 152
g01359108
Piston from a turbocharged engine

(X) Number
(Y) Number
1. Make a temporary mark on the components of

the piston and connecting rod assembly. This will
ensure that the components of each piston and
connecting rod assembly can be reinstalled in
the original cylinder. Note the correct orientation
of the connecting rod in relation to the piston.
Number (X) and number (Y) must be on the same
side. Refer to Illustration 151. Do not interchange
components.
Illustration 153
g01311807
Illustration 154
g00829406
Illustration 155
g01351357
Typical example
KENR6241
77
4. Place piston (2) on a suitable surface with the

crown upward. Use Tooling (B) in order to remove
compression rings (5) and (6), and oil control ring
(7) from the piston.
Note: Identify the orientation of the piston rings for
installation.
7. Inspect piston pin bearing (12) for wear or

damage. Refer to Specifications, Pistons and
Rings for more information. If necessary, replace
connecting rod (1) or replace piston pin bearing
(12).
If necessary, use Tooling (C) and a suitable press
to remove piston pin bearing (12) from connecting
rod (1).
8. Repeat Steps 1 through 7 in order to disassemble
the remaining pistons and connecting rods.
i02748593

- Assemble
Assembly Procedure
Table 41
Required Tools
Illustration 156
g01362961
Typical example
5. If necessary, remove nuts (11) and connecting rod

cap (10) from connecting rod (1).
6. Remove the lower half of connecting rod bearing
(9) from connecting rod cap (10). Remove the
upper half of connecting rod bearing (8) from
connecting rod (1). Keep the bearing shells
together.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distributor.
Illustration 157
Tool
Part Number
Part Description
Qty
Ring Expander
27610275
Driver Group
NOTICE
component life.
from wear or damage. If necessary, replace any
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distributor.
g01351358
78
Illustration 158
KENR6241
g01352211
2. If necessary, use Tooling (C) and a suitable press

to install piston pin bearing (12) into connecting
rod (1). Ensure that oil hole (Z) in the piston pin
bearing is aligned with the oil hole at the top of
the connecting rod.
Illustration 160
g01359107
Piston from a naturally aspirated engine

(X) Number
(Y) Number
Illustration 161
g01359108

(X) Number
(Y) Number
4. Place piston (2) on a suitable surface with the

crown downward. Ensure the correct orientation
of the connecting rod in the piston. Number
(X) and number (Y) must be on the same side.
Refer to Illustration 160 or Illustration 161. Install
connecting rod (1) and piston pin (3) to the piston.
Note: If the piston pin cannot be installed by hand,
heat the piston to a temperature of 45 5 C
(113 9 F). Do not use a torch to heat the piston.
Illustration 159
g01311807
Typical example
3. Lubricate piston pin bearing (12) and lubricate

the bore for the piston pin in piston (2) with clean
engine oil.
5. Use Tooling (A) in order to install retaining rings

(4) to the piston pin bore in piston (2).
Note: Ensure that the retaining rings are seated in
the grooves in the piston.
6. Follow Steps 6.a through 6.e in order to install the
piston rings to the piston.
KENR6241
79
Illustration 164
g00829406
b. Use Tooling (B) to install oil control ring (7) over

the spring.
Note: Ensure that the central wire is 180 degrees
from the ring gap.
Illustration 162
g01351357
d. Use Tooling (B) to install top compression ring

(5) into the top groove in the piston. The letter
T must be upward.
Illustration 163
c. Use Tooling (B) to install intermediate

compression ring (6) into the second groove in
the piston. The letter T and the chamfer on
the inner face of the ring must be upward.
g01352230
a. Position the spring for oil control ring (7) into the
oil ring groove in the piston. The central wire
must be located inside the end of the spring.
Illustration 165
g01359137
The correct position of the piston ring gaps

(AA) Ring gap of the top compression ring
(BB) Ring gap of the intermediate compression ring
(CC) Ring gap of the oil control ring
e. Align the piston ring gaps to the positions that

are shown in Illustration 165.
80
KENR6241
NOTICE
component life.
1. Ensure that the assemblies of the pistons and
connecting rods are clean and free from damage.
2. Apply clean engine oil to the cylinder bore, to the
piston rings, to the outer surface of the piston and
to the connecting rod bearings.
Note: Install the connecting rod bearings dry
when clearance checks are performed. Refer to
Disassembly and Assembly, Bearing Clearance Check. Apply clean engine oil to the connecting rod
bearings during final assembly.
g01362961
Illustration 166
Typical example
3. Rotate the crankshaft until the crankshaft pin

is in the bottom center position. Lubricate the
crankshaft pin with clean engine oil.
7. Install the upper half of connecting rod bearing

(8) to connecting rod (1).
8. Install the lower half of connecting rod bearing (9)
to connecting rod cap (10).
9. Repeat Steps 2 through 8 in order to assemble
the remaining pistons and connecting rods.
End By:
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, Piston and
Connecting Rods - Install.
Illustration 167
i02748594
g01352295

- Install
Table 42
Required Tools
Tool
Part Number
Part Description
Qty
21825491
Piston Ring Compressor
1
Illustration 168
g01359137
The correct position of the piston ring gaps

(AA) Ring gap of the top compression ring
(BB) Ring gap of the intermediate compression ring
(CC) Ring gap of the oil control ring
KENR6241
81
4. Align the piston ring gaps to the positions that

are shown in Illustration 168. Install Tooling (B)
onto piston (3). Ensure that Tooling (B) is installed
correctly and that the piston can easily slide from
the tool.

Balancer - Install.

rod bolts to protect the crankshaft pin from damage.
Ensure that the piston and the connecting rod
assembly are installed in the correct cylinder.
a. Install the oil strainer and install the engine oil pan.
Refer to Disassembly and Assembly, Engine Oil
Pan - Remove and Install.
5. Carefully push the piston and the connecting rod

assembly into the cylinder bore and onto the
crankshaft pin.
rod bolts to protect the crankshaft pin from damage.
Ensure that the piston and the connecting rod
assembly are installed in the correct cylinder.
End By:
b. Install the cylinder head. Refer to Disassembly

and Assembly, Cylinder Head - Install.
i02748595
Connecting Rod Bearings Remove

(Connecting rods in position)
Removal Procedure
Start By:
a. Remove the engine oil pan and remove the oil
b. If the engine is equipped with a balancer, remove
Balancer - Remove.
NOTICE
component life.
Illustration 169
g01352319
Typical example
6. Remove the tape or rubber tubing on the

connecting rod bolts. Install connecting rod cap
(1).
Note: Ensure that number (X) on the connecting
rod cap matches number (X) on the connecting rod.
Ensure that the numbers are on the same side.
7. Install nuts (2). Tighten the nuts to a torque of
54 Nm (40 lb ft).
Note: If all connecting rod bearings require

replacement, the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed
before changing from one pair of cylinders to
another pair of cylinders.. Refer to Disassembly
and Assembly, Connecting Rod Bearings - Install
for the correct procedure.
8. Ensure that the installed connecting rod assembly

has tactile side play. Rotate the crankshaft in order
to ensure that there is no binding.
9. Repeat Steps 2 through 8 in order to install the
remaining pistons and connecting rods.
82
KENR6241
i02748597
Connecting Rod Bearings Install

(Connecting rods in position)
NOTICE
component life.
Illustration 170
g01361963
Typical example
Note: The connecting rod and the connecting rod

cap have matching numbers at position (X). Note the
location of the connecting rod cap (5) for installation.
1. Rotate the crankshaft until the piston is at the
bottom center position. Remove nuts (6) and
remove connecting rod cap (5) from connecting
rod (1).
1. Inspect the pins of the crankshaft for damage.

Refer to Specifications, Connecting Rod Bearing
Journals for more information. If the crankshaft
is worn or damaged, replace the crankshaft or
recondition the crankshaft. Refer to Disassembly
and Assembly, Crankshaft - Remove and
Disassembly and Assembly, Crankshaft - Install.
2. Ensure that the connecting rod bearings are clean
replace the connecting rod bearings.
2. Remove lower connecting rod bearing (4) from

connecting rod cap (5).
Note: Use tape or rubber tubing on connecting rod
bolts (2) in order to protect the crankshaft journals.
The sharp edges of the connecting rod bolts could
damage the crankshaft journals.
3. Carefully push connecting rod (1) into the cylinder
bore. Remove upper connecting rod bearing (3)
from the connecting rod.
Illustration 171
g01361963
Typical example
3. Clean the bearing surface of connecting rod (1)

and connecting rod cap (5).
4. Install upper connecting rod bearing (3) to
connecting rod (1). Lubricate the bearing surface
of the connecting rod bearing with clean engine oil.
KENR6241
Note: Use tape or rubber tubing on connecting rod

bolts (2) in order to protect the crankshaft journals.
The sharp edges of the connecting rod bolts could
damage the crankshaft journals.
5. Carefully pull connecting rod (1) against the
crankshaft pin.
6. Install lower connecting rod bearing (4) to
connecting rod cap (5).
7. Lubricate the pin of the crankshaft and lubricate
lower connecting rod bearing (4) with clean engine
oil.
NOTICE
When the connecting rod caps are installed, ensure
that the identification marks are aligned.
8. Ensure that the numbers at position (X) on
connecting rod cap (5) and on connecting rod (1)
match. Install connecting rod cap (5).
9. Install nuts (6). Tighten the nuts evenly to a torque
of 54 Nm (40 lb ft).
10. Repeat Steps 2 through 9 for the remaining
connecting rod bearings.
Note: If all connecting rod bearings require
replacement, the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders.
1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed
before changing from one pair of cylinders to
another pair of cylinders. Refer to Disassembly
and Assembly, Connecting Rod Bearings - Remove
for the correct procedure.
11. Ensure that the installed connecting rod
assemblies have tactile side play. Carefully rotate
the crankshaft in order to ensure that there is no
binding.
83
i02748598
Crankshaft Main Bearings Remove and Install

(Crankshaft in position)
Removal Procedure
Start By:
a. If the engine is equipped with a balancer, remove
with a balancer, remove the oil strainer. Refer to
Disassembly and Assembly, Engine Oil Pan Remove and Install.
b. Remove the flywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing
NOTICE
This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are removed.
NOTICE
component life.
1. Ensure that the main bearing caps are marked for
the correct location and orientation.
End By:
a. If the engine is equipped with a balancer, Install
Balancer - Install.
b. Install the oil strainer and the engine oil pan. Refer
Illustration 172
g01353474
Typical example
84
KENR6241
2. Remove bolts (1). Remove main bearing cap (2)

from the cylinder block.
Note: The lower main bearing is a plain bearing that

has no oil holes.
Note: Number five main bearing cap must be

removed squarely from the cylinder block. Do not
twist the main bearing cap during removal as damage
may result.
g01353517
Illustration 175
Typical example
5. Push out upper main bearing (6) with a suitable

tool from the side opposite the locating tab.
Carefully rotate the crankshaft while you push on
the bearing. Remove upper main bearing (6) from
the cylinder block. Keep the bearings together.
Illustration 173
g01353478
Number five main bearing cap
3. For number five main bearing cap, remove lower

thrust washers (4) and remove seals (3).
Note: It is not possible to remove the upper thrust
washer from the cylinder block with the crankshaft
in position. If the upper thrust washer requires
removal, the crankshaft must be removed. Refer to
Disassembly and Assembly, Crankshaft - Remove.
Note: Do not damage the machined surfaces of the

crankshaft during removal of the upper main bearing.
The upper main bearing has a groove and two oil
holes.
Table 43
Required Tools
Tool
Part Number
Part Description
Qty
218260238
POWERPART
Silicone Sealant
Adhesive
27610013
Seal Installer
21825617
NOTICE
This procedure must only be used to remove and install the main bearing shells with the crankshaft in position.
The removal procedure and the installation procedure
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are removed.
Illustration 174
g01353475
4. Remove lower main bearing (5) from main bearing

cap (2). Keep the main bearing and the main
bearing cap together.
KENR6241
85
4. Install lower main bearing (5) into main bearing

cap (2). Ensure that the locating tab for the lower
main bearing is correctly seated into the slot in
the bearing cap.
NOTICE
component life.
Note: The lower main bearing is a plain bearing that

has no oil holes.
1. Ensure that the main bearings are clean and free

from wear or damage. If necessary, replace the
main bearings.
2. Clean the journal of the crankshaft. Inspect the
journal of the crankshaft for damage. If necessary,
replace the crankshaft or recondition the
crankshaft. Refer to Disassembly and Assembly,
Crankshaft - Remove for more information.
Illustration 178
g01353916
5. For number five main bearing cap, follow Steps

5.a through 5.c in order to install the lower thrust
washers (4) to the main bearing cap.
Illustration 176
g01353517
Typical example
3. Lubricate the crankshaft journal and the upper

main bearing (6) with clean engine oil. Slide the
upper main bearing into position between the
crankshaft journal and the cylinder block. Ensure
that the locating tab for the upper main bearing is
correctly seated in the slot in the cylinder block.
Note: The upper main bearing has a groove and two
oil holes.
Illustration 177
Note: It is not possible to install the upper thrust

washer to the cylinder block with the crankshaft in
position. If the upper thrust washer requires removal
and installation, the crankshaft must be removed.
Refer to Disassembly and Assembly, Crankshaft Remove.
a. Ensure that lower thrust washers (4) are clean
replace the thrust washers. Lubricate the thrust
washers with clean engine oil.
b. Install lower thrust washers (4) to main bearing
cap (2). Ensure that holes (X) in the thrust
washers are aligned with dowels (Y) in the
main bearing cap. Ensure that the grooves in
the thrust washers face toward the crankshaft.
g01353475
86
Illustration 179
KENR6241
g01354237
c. Ensure that the recess in the cylinder block for

number five main bearing cap is clean and dry.
Apply a bead of Tooling (A) to the corners of
the recess at positions (Z).
Illustration 181
g01354238
Typical example
8. Use Tooling (B) in order to push seals (3) fully into

the grooves.
6. Lubricate the crankshaft journal and the lower

main bearing with clean engine oil. Install main
bearing cap (2) to the cylinder block. Ensure the
correct orientation of the main bearing cap. The
locating tab for the upper and the lower bearing
should be on the same side of the engine.
Illustration 182
g01353474
Typical example
9. Lubricate the threads of bolts (1) with clean engine

oil. Lubricate the underside of the heads of the
bolts with clean engine oil.
Illustration 180
g01359531
Typical example
7. Inject a small quantity of Tooling (A) into the two

grooves in number five main bearing cap. Position
new seals (3) in the grooves. Ensure that rounded
edges of the seals are outward. Push the first
25 mm (1 inch) of the seal into the grooves by
hand.
10. Install bolts (1) to main bearing cap (2). Evenly

tighten the bolts in order to pull the main bearing
cap into position. Ensure that the main bearing
cap is correctly seated.
For number five main bearing cap, Ensure that
the rear face of the main bearing cap is flush with
the rear face of the cylinder block.
Note: Do not tap the main bearing cap into position
as the bearing may be dislodged.
KENR6241
87
Start By:
12. Rotate the crankshaft in order to ensure that there

is no binding.
a. Remove the rocker shaft and pushrods. Refer to

Pushrod - Remove.
b. If the engine is equipped with a balancer, remove
with a balancer, remove the oil strainer. Refer to
Disassembly and Assembly, Engine Oil Pan Remove and Install.
c. Remove the flywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing
g01359530
Illustration 183
Typical example
13. Check the crankshaft end play. Refer to

Specifications, Crankshaft for more information.
Push the crankshaft toward the front of the engine.
Install Tooling (C). Push the crankshaft toward the
rear of the engine in order to measure the end
play.
d. Remove the front plate. Refer to Disassembly and

Assembly, Front Plate - Remove.
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.
NOTICE
End By:
a. If the engine is equipped with a balancer, install
Balancer - Install. If the engine is not equipped
with a balancer, install the oil strainer and install
the engine oil pan. Refer to Disassembly and
Assembly, Engine Oil Pan - Remove and Install.

component life.
b. Install the flywheel housing. Refer to Disassembly

and Assembly, Flywheel Housing - Remove and
Install.

rod bolts to protect the crankshaft journals from
damage.
i02748599
Crankshaft - Remove
Table 44
Required Tools
Part
Number
Part Description
Lifting Sling
2. If necessary, remove the cylinder head. Refer

to Disassembly and Assembly, Cylinder Head Remove. Remove the pistons and connecting
rods. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Remove.
If the cylinder head, the pistons and the
connecting rods have not been removed, remove
the connecting rod caps. Refer to Disassembly
and Assembly, Connecting Rod Bearings
- Remove. Carefully push the piston and
connecting rod assemblies into the cylinder bores.
Removal Procedure
Tool
1. The engine should be mounted on a suitable

Qty
1
88
Illustration 184
KENR6241
g01359995
3. Ensure that bearing caps (2) are marked for the

location and orientation.
4. Remove bolts (1) from bearing caps (2).
5. Remove bearing caps (2) from the cylinder block.
Note: Number five main bearing cap must be
removed squarely from the cylinder block. Do not
twist the main bearing cap during removal as damage
may result.
Illustration 186
g01359996
7. Attach a Tooling (A) and a suitable lifting device to

crankshaft (3). Carefully lift the crankshaft out of
the cylinder block. The weight of the crankshaft is
Note: Do not damage the finished surfaces on the
crankshaft.
Illustration 187
g01359993
Typical example
8. Remove upper main bearings (7). Keep the upper

main bearings and the upper thrust washer with
the respective main bearing caps.
For number five main bearing, remove the upper
thrust washer from the rear of the cylinder block.
Illustration 185
g01359992
Note: The upper main bearings have a groove and

two oil holes.
6. Remove lower main bearings (4) from main

bearing caps (2). Keep the main bearings and the
main bearing caps together.
For number five main bearing cap, remove lower
thrust washers (5) and remove seals (6).
Note: The lower main bearings are plain bearings
with no oil holes.
KENR6241
89
i02748601
Crankshaft - Install
Table 45
Required Tools
Tool
Part Number
Part Description
Qty
21826038
POWERPART
Silicone Sealant
Adhesive
27610013
Seal Installer
21825617
Illustration 188
g01360029
Typical example
NOTICE
5. Install upper bearings (7) to the cylinder block.

Ensure that the locating tabs for the upper
bearings are seated in the slots in the cylinder
block.

component life.
Note: The upper bearings have a groove and two

oil holes.
Note: The engine should be mounted on a suitable

1. Clean the crankshaft and inspect the crankshaft
for wear or damage. Refer to Specifications,
Crankshaft for more information. If necessary,
replace the crankshaft or recondition the
crankshaft.
6. Lubricate upper thrust washer (8). Install the upper

thrust washer to the rear of the cylinder block with
the oil grooves toward the outside. Ensure that
holes (X) in the thrust washer are aligned with
dowels (Y) in the cylinder block.
7. Lubricate upper bearings (7) with clean engine oil.
2. Ensure that the parent bores for the crankshaft

bearings in the cylinder block are clean. Ensure
that the threads for the bearing bolts in the cylinder
block are clean and free from damage.
3. Clean the crankshaft bearings and the thrust
washers. Inspect the bearings and the thrust
washers for wear or damage. If necessary, replace
the bearings and the thrust washers.
Note: If the crankshaft bearings are replaced, check
whether oversize bearings were previously installed.
If the thrust washers are replaced, check whether
oversize thrust washers were previously installed.
4. Ensure that all of the lubrication passages are
clean and free of debris.
Illustration 189
g01359996
Typical example
8. Attach Tooling (A) and a suitable lifting device to

crankshaft (3). Carefully lift the crankshaft into
the cylinder block. The weight of the crankshaft is
approximately 32 kg (70 lb). Remove Tooling (A).
Note: Do not damage any of the finished surfaces on
the crankshaft. Do not damage the bearings.
90
Illustration 190
KENR6241
g01359992
9. Install lower bearings (4) to main bearing caps

(2). Ensure that the locating tabs for the lower
bearings are seated in the slots in the bearing
caps.
Note: The lower bearings are plain bearing with no
oil holes.
10. For number five main bearing cap, follow Steps
10.a through 10.c in order to install the lower
thrust washers (5) to the main bearing cap.
Illustration 191
g01354237
c. Apply a bead of Tooling (A) to the corners of

the recess in the cylinder block at positions (Z).
11. Lubricate the crankshaft journals and the lower
main bearings with clean engine oil. Install main
bearing caps (2) to the cylinder block. Ensure the
correct orientation of the main bearing caps. The
locating tab for the upper and the lower bearing
should be on the same side of the engine.
Note: For number five main bearing cap, ensure that
the rear face of the main bearing cap is flush with the
rear face of the cylinder block.
a. Ensure that lower thrust washers (5) are clean

replace the thrust washers. Lubricate the thrust
washers with clean engine oil.
b. Install lower thrust washers (5) to main bearing
cap (2). Ensure that holes (X) in the thrust
washers are aligned with dowels (Y) in the
main bearing cap.
Illustration 192
g01359531
Typical example
12. Inject a small quantity of Tooling (A) into the two

grooves in number five main bearing cap. Position
new seals (3) in the grooves. Ensure that rounded
edges of the seals are outward. Push the first
25 mm (1 inch) of the seal into the grooves by
hand.
KENR6241
91
Illustration 195
g01359530
Typical example
Illustration 193
g01354238
Typical example
13. Use Tooling (B) in order to push seals (3) fully

into the grooves.
18. Check the crankshaft end play. Refer to

Specifications, Crankshaft for more information.
Push the crankshaft toward the front of the engine.
Install Tooling (A). Push the crankshaft toward the
rear of the engine in order to measure the end
play.
19. If the crankshaft has been replaced or the
crankshaft has been reconditioned, inspect
the height of the pistons above the cylinder
block. Refer to Systems Operation, Testing
and Adjusting, Piston Height - Inspect for
more information. First install the pistons and
connecting rods. Refer to Disassembly and
Assembly, Pistons and Connecting Rods - Install.
Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
If the crankshaft has not been replaced or the
crankshaft has not been reconditioned, install the
connecting rod caps. Refer to Disassembly and
Assembly, Connecting Rod Bearings - Install.
Illustration 194
g01353474
Typical example
14. Lubricate the threads of bolts (1) with clean

engine oil. Lubricate the underside of the heads
of the bolts with clean engine oil.
15. Install bolts (1) to main bearing caps (2). Evenly
tighten the bolts in order to pull the main bearing
caps into position. Ensure that the caps are
correctly seated.
Note: Do not tap the main bearing caps into position
as the bearing may be dislodged.
17. Rotate the crankshaft in order to ensure that there
is no binding.
End By:
a. Install the front plate. Refer to Disassembly and
Assembly, Front Plate - Install.
b. Install the flywheel housing. Refer to Disassembly
and Assembly, Flywheel Housng - Remove and
Install.
c. If the engine has a balancer, install the balancer.
Refer to Disassembly and Assembly, Balancer Install. If the engine does not have a balancer,
install the oil strainer and install the engine oil pan.
Refer to Disassembly and Assembly, Engine Oil
Pan - Install.
d. Install the rocker shaft and pushrods. Refer to
Push Rod - Install.
92
KENR6241
i02748602
Crankshaft Gear - Remove and

Install
4. If necessary, remove the keys (not shown) from

crankshaft (2).
NOTICE
Removal Procedure

component life.
Table 46
Required Tools
Tool
Part Number
Part Description
Qty
Combination Puller
Start By:
a. Remove the idler gear. Refer to Disassembly and
Note: In this procedure, the crankshaft gear is
removed with the crankshaft in the engine.
NOTICE
Illustration 197

component life.
Balancer - Remove.
g01344011
Typical example
1. If necessary, install the keys (not shown) to

crankshaft (2).

2. Raise the temperature of crankshaft gear (1) in an
oven to 100 C (212 F).
3. Align the keyway in crankshaft gear (1) with the
keys in crankshaft (2). Install crankshaft gear (1).
Ensure that the crankshaft gear is seated squarely
against the crankshaft.
Illustration 196
g01343991

Balancer - Install.
Typical example
End By:
3. Use Tooling (A) to remove crankshaft gear (1)

from crankshaft (2).
a. Install the idler gear. Refer to Disassembly and

Assembly, Idler Gear- Remove and Install.
KENR6241
93
i02748526
Ensure that the bearing locking tabs are properly

seated in the tab grooves.
Bearing Clearance - Check
The crankshaft must be free of oil at the contact

points of Tooling (A).
Measurement Procedure
1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.
Table 47
Note: Do not allow Tooling (A) to extend over the

edge of the bearing.
Required Tools
Tool
Part
Number
Part Description
Qty
Plastic Gauge (Green)

0.025 to 0.076 mm
(0.001 to 0.003 inch)
Plastic Gauge (Red)

0.051 to 0.152 mm
(0.002 to 0.006 inch)
Plastic Gauge (Blue)

0.102 to 0.229 mm
(0.004 to 0.009 inch)
Plastic Gauge (Yellow)

0.230 to 0.510 mm
(0.009 to 0.020 inch)
2. Use the correct torque-turn specifications in order

to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A)
is installed.
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 198.
NOTICE
component life.
Note: Perkins does not recommend the checking of
the actual clearances of the bearing shells particularly
on small engines. This is because of the possibility
of obtaining inaccurate results and of damaging the
bearing shell or the journal surfaces. Each Perkins
bearing shell is quality checked for specific wall
thickness.
Note: The measurements should be within
specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
Illustration 198
g01152855
Typical Example
4. Remove all of Tooling (A) before you install the

bearing cap.
Note: When Tooling (A) is used, the readings can
sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, Connecting Rod Bearing Journal and
Specifications Manual, Main Bearing Journal for the
correct clearances.
The technician must be very careful to use Tooling (A)

correctly. The following points must be remembered:
Ensure that the backs of the bearings and the

bores are clean and dry.
94
KENR6241
i02748603
Coolant Temperature Sensor Remove and Install

Removal Procedure
Table 48
Required Tools
Tool
Part Number
21820122
Part Description
POWERPART
Pipe Sealant
Qty
1
1. Ensure that the coolant temperature sensor is

NOTICE
component life.
NOTICE
mandates.
System Coolant - Change.
Illustration 200
g01343990
Typical example
2. Apply a thin layer of Tooling (A) to the threads of

coolant temperature sensor (1).
3. Install coolant temperature sensor (1) into the
cylinder head. Tighten the coolant temperature
sensor to a torque of 11 Nm (97 lb in).
4. Connect the harness assembly (not shown) to
coolant temperature sensor (1).
5. Fill the cooling system to the correct level. Refer
System Coolant - Change.
i02748604
Illustration 199
g01343990
Typical example
2. Disconnect the harness assembly (not shown)

from coolant temperature sensor (1).
3. Remove coolant temperature sensor (1) from the
cylinder head.
Engine Oil Pressure Sensor Remove and Install

Removal Procedure
NOTICE
component life.
KENR6241
95
NOTICE
mandates.
Illustration 202
g01343988
Typical example
2. Apply a thin layer of Tooling (A) to the threads of

engine oil pressure sensor (1).
3. Install engine oil pressure sensor (1) to the
cylinder block. Use a deep socket in order to
tighten the engine oil pressure sensor to a torque
of 11 Nm (97 lb in).
g01343988
Illustration 201
Typical example
1. Remove the harness assembly (not shown) from

2. Use a deep socket in order to remove engine oil
pressure sensor (1) from the cylinder block.
Required Tools
Part Number
21820122
Part Description
i02748605
Glow Plugs - Remove and

Install
Removal Procedure
Table 49
Tool
4. Connect the harness assembly (not shown) to

Qty
POWERPART
Pipe Sealant
NOTICE
NOTICE
component life.
position.

component life.
1. Ensure that the engine oil pressure sensor is
96
KENR6241
g01343974
Illustration 203
Naturally aspirated engine
Illustration 205
g01343974
Naturally aspirated engine
g01343965
Illustration 204
Illustration 206
g01343965
Turbocharged engine
Turbocharged engine
2. Remove nuts (1) and bus bar (2).
2. Install glow plugs (3) to the cylinder head.
3. Use a deep socket in order to remove glow plugs

(3) from the cylinder head.
3. For naturally aspirated engines, use a deep socket

in order to tighten the glow plugs to a torque of
18 Nm (13 lb ft).
For turbocharged engines, use a deep socket

in order to tighten the glow plugs to a torque of
25 Nm (18 lb ft).
Table 50
Required Tools
Tool
Part Number
27610296
Part Description
Torque Wrench
Qty
1
NOTICE
4. Position bus bar (2) onto glow plugs (3) and install
nuts (1). Use Tooling (A) to tighten the nuts to a
torque of 1.2 Nm (11 lb in).
position.

component life.
1. Ensure that the threads of the glow plugs are clean
and free from damage. Replace any damaged
glow plugs.
KENR6241
97
i02748606
V-Belts - Remove and Install

Removal Procedure
NOTICE
component life.
Illustration 208
g01343666
Typical example
1. Install V-belt (3) onto the pulleys.

Note: A used V-belt should be installed in the original
direction of rotation.
2. Adjust the tension of V-belt (3) by moving the
alternator away from the engine. Use Tooling (A)
in order to achieve the correct belt tension. Refer
to Specifications, Belt Tension Chart for more
information.
g01343666
Illustration 207
Typical example
3. Tighten bolts (1), and (2) to a torque of 11 Nm

(97 lb in). Tighten bolt (4), to a torque of 35 Nm
(26 lb ft).
1. Loosen bolts (1), (2) and (4). Slide the alternator

toward the engine.
i02748608
Fan - Remove and Install
2. Remove V-belt (3).

Note: Mark the direction of rotation if the V-belt will
be reused.
Removal Procedure
Start By:
Table 51
Required Tools
Tool
Part Number
Part Description
Belt Tension Gauge
Qty
a. Remove the V-Belt. Refer to Disassembly and

Assembly, V-Belts - Remove and Install.
NOTICE
component life.
98
Illustration 209
KENR6241
g01343637
Illustration 210
g01343637
Typical example
Typical example
1. Remove bolts (5) and plate (6).
2. Position fan pulley (3) onto water pump (4).
2. Remove fan (1). Note the orientation of the fan

for installation.
3. If the engine is equipped with a spacer, position

spacer (2) onto pulley (3).
3. If the engine is equipped with a spacer, remove

spacer (2).
4. Install fan (1), plate (6), and bolts (5).
4. Remove pulley (3) from water pump (4).
1. Ensure that all components are free from wear or
damage. If necessary, replace any components
that are worn or damaged.
Note: Ensure that the fan is correctly oriented.

End By:
a. Install the V-Belt. Refer to Disassembly and
i02748609
Alternator - Remove and Install

Removal Procedure
Start By:
a. Remove the V-Belt. Refer to Disassembly and
NOTICE
component life.
KENR6241
99

position.
2. Make temporary identification marks on the

connections of the harness assembly.
Illustration 212
g01343570
Typical example
Illustration 211
g01343570
Typical Example
3. Disconnect the harness assembly from alternator

(3).
4. Loosen bolt (4). Remove bolt (1) and washer (2)
from alternator (3).
5. Remove bolt (5) from alternator (3). Remove the
alternator from alternator bracket (6).
1. Position alternator (3) on bracket (6) and install

bolt (5) finger tight.
2. Install bolt (1) and washer (2) finger tight.
3. Install the V-belt. Refer to Disassembly and
assembly, V-belts - Remove and Install for the
correct procedure.
4. Tighten bolts (1) and (4) to a torque of 11 Nm
(97 lb in). Tighten bolt (5) to a torque of 35 Nm
(26 lb ft).
5. Connect the harness assembly to alternator (3).
position.
100
KENR6241
i02748611
Electric Starting Motor Remove and Install

Removal Procedure
Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative () battery terminal. Completely tape all metal surfaces of the
disconnected battery cable end in order to prevent
contact with other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch
location to inform personnel that the equipment is
being worked on.
1. Disconnect the battery.
2. Make temporary identification marks on the
harness assemblies that are connected to the
electric starting motor. Disconnect the harness
assemblies from the electric starting motor.
Illustration 213
Illustration 214
g01343546
Typical example
1. If necessary, install studs (2).

2. Align electric starting motor (1) to studs (2). Install
the electric starting motor.
3. Install nuts (3). Tighten the nuts to a torque of
35 Nm (26 lb ft).
4. Connect the harness assemblies to the electric
starting motor. Refer to Specifications, Electric
Starting Motor for the tightening torques of the
terminal nuts.
5. Connect the battery.
g01343546
Typical example
3. Remove nuts (3) from electric starting motor (1).

Note: Support the weight of the electric starting
motor as the nuts are removed.
4. Remove electric starting motor (1).
5. If necessary, remove studs (2).
KENR6241
101
Index Section
Index
A
Alternator - Remove and Install ............................. 98
Installation Procedure ........................................ 99
Removal Procedure ........................................... 98
B
Balancer - Assemble .............................................
Assembly Procedure..........................................
Balancer - Disassemble.........................................
Disassembly Procedure .....................................
Balancer - Install....................................................
Installation Procedure ........................................
Balancer - Remove................................................
Removal Procedure ...........................................
Bearing Clearance - Check ...................................
Measurement Procedure ...................................
72
72
71
71
73
73
70
70
93
93
C
Camshaft - Remove and Install ............................. 65
Camshaft Gear - Remove and Install .................... 66
Connecting Rod Bearings - Install (Connecting rods
in position) ........................................................... 82
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................... 81
Coolant Temperature Sensor - Remove and
Install ................................................................... 94
Crankcase Breather - Remove and Install
(Turbocharged Engines) ...................................... 54
Crankshaft - Install................................................. 89
Crankshaft - Remove............................................. 87
Crankshaft Front Seal - Remove and Install.......... 47
Crankshaft Gear - Remove and Install .................. 92
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position)........................................ 83
Crankshaft Pulley - Remove and Install ................ 45
Crankshaft Rear Seal - Remove and Install ..........

Crankshaft Wear Sleeve (Rear) - Remove and
Install ...................................................................
Cylinder Head - Install ...........................................
Cylinder Head - Remove .......................................
40
41
40
42
42
42
62
62
60
60
D
Disassembly and Assembly Section........................ 4
E
Electric Starting Motor - Remove and Install ....... 100
Installation Procedure ...................................... 100
Removal Procedure ......................................... 100
Engine Oil Bypass Valve - Remove and Install ..... 32
Engine Oil Cooler - Install...................................... 30
Engine Oil Cooler - Remove.................................. 29
Engine Oil Filter Base - Remove and Install.......... 28
Engine Oil Pan - Remove and Install..................... 67
Installation Procedure for the Engine Oil Pan .... 69
Installation Procedure for the Oil Strainer .......... 69
Removal Procedure for the Engine Oil Pan ....... 67
Removal Procedure for the Oil Strainer ............. 68
Engine Oil Pressure Sensor - Remove and Install.. 94
Engine Oil Pump - Install ....................................... 34
Engine Oil Pump - Remove ................................... 33
Engine Oil Relief Valve - Remove and Install ........ 31
Exhaust Manifold - Remove and Install ................. 20
F
Fan - Remove and Install ......................................
Flywheel - Install....................................................
97
98
97
39
39
102
Index Section
Flywheel - Remove................................................ 38
Flywheel Housing - Remove and Install ................ 43
Front Cover - Remove and Install.......................... 48
Front Plate - Install ................................................ 53
Front Plate - Remove ............................................ 52
Fuel Injection Lines - Remove and Install (Naturally
Aspirated Engines) ................................................ 5
Installation Procedure .......................................... 6
Removal Procedure ............................................. 5
Fuel Injection Lines - Remove and Install
(Turbocharged Engines) ........................................ 7
Fuel Injection Pump - Install .................................. 14
Fuel Injection Pump - Install (Fuel Injection Pumps
With a Water Heated Cold Start Device) ............. 13
Fuel Injection Pump - Remove ................................ 9
Fuel Injection Pump - Remove (Fuel Injection Pumps
With a Water Heated Cold Start Device) .............. 11
Removal Procedure ............................................ 11
Fuel Injector - Remove and Install (Naturally
Aspirated Engines) .............................................. 16
Fuel Injector - Remove and Install (Turbocharged
Engines)............................................................... 16
Fuel Priming Pump and Fuel Filter Base - Remove
and Install .............................................................. 4
G
Glow Plugs - Remove and Install .......................... 95
H
Housing (Front) - Remove and Install.................... 51
KENR6241
I
Idler Gear - Remove and Install............................. 48
Important Safety Information ................................... 2
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 23
Inlet and Exhaust Valves - Remove and Install ..... 25
Inlet Manifold - Remove and Install ....................... 21
L
Lifter Group - Remove and Install.......................... 64
P
Pistons and Connecting Rods - Assemble ............
Pistons and Connecting Rods - Disassemble .......
Pistons and Connecting Rods - Install...................
Pistons and Connecting Rods - Remove...............
77
77
75
75
80
80
74
74
R
Rocker Shaft - Assemble.......................................
Rocker Shaft - Disassemble ..................................
Rocker Shaft and Pushrod - Install........................
Rocker Shaft and Pushrod - Remove....................
58
58
57
57
59
59
56
56
T
Table of Contents..................................................... 3
Turbocharger - Install ............................................ 19
Turbocharger - Remove ........................................ 17
KENR6241
103
Index Section
V
V-Belts - Remove and Install .................................
Valve Mechanism Cover - Remove and Install......
97
97
97
55
56
55
W
Water Pump - Remove and Install......................... 35
Water Temperature Regulator Housing - Remove and
Install ................................................................... 37
Copyright 2007 Perkins Engine Company Limited

All Rights Reserved
Printed in U.K.

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KENR6241

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Camshaft Gear - Remove and Install .................. 66

Disassembly and Assembly

Fuel Priming Pump and Fuel

3. Drain fuel filter (4). Refer to Operation and

2. Turn the battery disconnect switch to the OFF

2. Position fuel filter base (3) on the mounting

Fuel Injection Lines - Remove

Note: Place identification marks on all tube

3. Disconnect hose (4) from tube assembly (6).

Note: Do not allow the unions to turn in the fuel

Injector Pipe Nut Tool

1. Remove the caps from fuel injectors (3) and install

2. Position fuel return line (2) onto fuel injectors (3).

7. Tighten banjo bolt (9) to a torque of 18 Nm

Fuel Injection Lines - Remove

Injector Pipe Nut Tool

2. If necessary, loosen the dipstick tube (not shown).

6. Use suitable caps in order to plug the open ports

Fuel Injection Pump - Remove

1. Install hoses (2) to fuel injectors (3).

Dispose of all fluids according to local regulations and

2. Position tube assembly (6) onto the engine and

3. Connect tube assembly (6) to fuel injectors (3).

Contaminants may cause rapid wear and shortened

5. Install clamps (4). Tighten the clamps securely.

2. Remove bolts (4).

6. Loosen bolt (7).

3. Remove plate (2) from front housing (1).

7. Remove fasteners (8), bolt (10) and bracket (9).

4. Remove O-ring seal (3) from plate (2).

8. Support fuel injection pump (6) and remove bolt

Timing marks on the gears

5. Ensure that Timing marks (X) on the teeth of the

10. Remove O-ring seal (13) from housing (5).

Note: Do not remove the nut at this time.

1. Drain the coolant from the cooling system into a

13. If the original fuel injection pump will be installed,

Fuel Injection Pump - Remove

4. Ensure that number one piston is at the top

2. Loosen the hose clamps and disconnect hoses (1)

5. Remove bolts (8).

Timing marks on the gears

8. Ensure that Timing marks (X) on the teeth of the

13. Remove O-ring seal (16) from housing (9).

17. Remove housing (9) from fuel injection pump (2).

9. Loosen bolt (10).

Fuel Injection Pump - Install

6. Install a new O-ring seal (16) to housing (9). Install

Timing marks on the gears

2. Ensure that the mating surfaces of housing (9)

7. Install the assembly of housing (9) and fuel

5. Tighten nuts (18) to a torque of 18 Nm (13 lb ft).

15. Fill the cooling system with coolant. Refer to

Fuel Injection Pump - Install

10. Install a new O-ring seal (7) to plate (6).

11. Position plate (6) on front housing (5). Install

Contaminants may cause rapid wear and shortened

12. Tighten bolt (10) to a torque of 18 Nm (13 lb ft).

1. Ensure that number one piston is at the top

13. Install hose (3) to fuel injection pump (2). Tighten