SENR9973-01 September 2007 Disassembly and Assembly 400C Industrial Engine HB (Engine) HD (Engine) HH (Engine) HL (Engine) HM (Engine) HN (Engine) HP (Engine) HR (Engine)
Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by 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.
SENR9973-01 3 Table of Contents Table of Contents Fuel Priming Pump - Remove... 4 Fuel Priming Pump - Install... 4 Fuel Filter Base - Remove... 5 Fuel Filter Base - Install... 6 Fuel Injection Lines - Remove and Install... 7 Fuel Shutoff Solenoid - Remove and Install... 9 Fuel Injection Pump - Remove... 10 Fuel Injection Pump - Install... 11 Fuel Injector - Remove... 12 Fuel Injector - Install... 12 Turbocharger - Remove and Install... 13 Exhaust Manifold - Remove and Install... 15 Inlet and Exhaust Valve Springs - Remove and Install... 17 Inlet and Exhaust Valves - Remove and Install... 19 Engine Oil Line - Remove and Install... 21 Engine Oil Cooler - Remove and Install... 23 Engine Oil Relief Valve - Remove and Install... 24 Engine Oil Pump - Remove... 24 Engine Oil Pump - Install... 26 Water Pump - Remove... 28 Water Pump - Install... 30 Water Temperature Regulator Housing - Remove and Install... 31 Water Temperature Regulator - Remove and Install... 32 Flywheel - Remove... 35 Flywheel - Install... 36 Crankshaft Rear Seal - Remove... 37 Crankshaft Rear Seal - Install... 37 Flywheel Housing - Remove and Install... 39 Crankshaft Pulley - Remove and Install... 42 Crankshaft Front Seal - Remove... 43 Crankshaft Front Seal - Install... 43 Housing (Front) - Remove... 44 Housing (Front) - Disassemble... 45 Housing (Front) - Assemble... 47 Housing (Front) - Install... 50 Crankcase Breather - Remove and Install... 51 Valve Mechanism Cover - Remove and Install... 54 Rocker Shaft and Pushrod - Remove... 55 Rocker Shaft - Disassemble... 56 Rocker Shaft - Assemble... 57 Rocker Shaft and Pushrod - Install... 59 Cylinder Head - Remove... 60 Cylinder Head - Install... 61 Lifter Group - Remove and Install... 63 Camshaft - Remove... 64 Camshaft - Disassemble... 65 Camshaft - Assemble... 66 Camshaft - Install... 66 Engine Oil Pan - Remove and Install... 67 Pistons and Connecting Rods - Remove... 68 Pistons and Connecting Rods - Disassemble... 69 Pistons and Connecting Rods - Assemble... 71 Pistons and Connecting Rods - Install... 73 Connecting Rod Bearings - Remove... 74 Connecting Rod Bearings - Install... 75 Crankshaft Main Bearings - Remove... 76 Crankshaft Main Bearings - Install... 77 Crankshaft - Remove... 78 Crankshaft - Install... 80 Bearing Clearance - Check... 81 Coolant Temperature Switch - Remove and Install... 82 Engine Oil Pressure Switch - Remove and Install... 84 Glow Plugs - Remove and Install... 86 V-Belts - Remove and Install... 86 Fan - Remove and Install... 87 Alternator - Remove and Install... 91 Electric Starting Motor - Remove and Install... 101 Index Section Index... 103
4 SENR9973-01 Disassembly and Assembly Section i02186288 FuelPrimingPump-Remove Removal Procedure 2. Install suitable plugs into the fuel lines in order to prevent contamination. 3. Remove the two setscrews (4) that fasten the fuel priming pump (1) to the cylinder block. Note: The fuel priming pump can be oriented in two positions. Before removing the fuel priming pump (1) from the cylinder block, note the orientation of the flange (2) of the fuel priming pump (1) for assembly. 4. Remove the fuel priming pump (1) and the O-ring (3). Discard the O-ring. Note: In order to remove the fuel priming pump from the engine, it may be necessary to rotate the crankshaft until the operating plunger of the fuel priming pump is not under pressure. 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. i02186279 Fuel Priming Pump - Install Installation Procedure Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 1 g00824616 1. Loosen the hose clamps and remove the two fuel lines from the fuel priming pump (1). Note the positions of the fuel inlet and the fuel outlet for installation.
SENR9973-01 5 Fuel Filter Base - Remove i02186242 Removal Procedure Illustration 2 g01129954 1. Clean the mating surfaces of the fuel priming pump on the cylinder block and clean the flange (2) of the fuel priming pump. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Note: Ensure that the camshaft lobe for the fuel priming pump is at minimum lobe lift before the fuel priming pump is installed. The fuel priming pump canbeorientedintwopositions.ensurethatthefuel primingpumpisorientedinthecorrectposition. 2. Install a new O-ring (3) to the fuel priming pump(1). 3. Lubricate the operating plunger of the fuel priming pump (1) with clean engine oil. 4. Install the fuel priming pump (1) to the engine. Ensure that the operating plunger is positioned correctly on the camshaft lobe. 5. Install the two setscrews (4) that fasten the fuel priming pump (1) to the cylinder block. Tighten the setscrews to a torque of 6 N m (4.5 lb ft). 6. Loosely install the hose clamps to the fuel lines. Connect the appropriate fuel lines to the fuel inlet and the fuel outlet of the fuel priming pump (1). Tighten the hose clamps. Note: The fuel inlet for the fuel priming can be rotated 360 degrees by loosening setscrew (5). The fuel inlet is adjustable in 15 degree increments. If adjustment is made to the position of the fuel inlet, tighten setscrew (5) to a torque of 2.5 N m (22 lb in). 7. Prime the fuel system. Refer to Testing and Adjusting, Fuel System - Prime for additional information. Illustration 3 g01118406 1. Disconnect the fuel lines (1) and (2). Inspect the condition of the rubber olives (not shown) that seal the fuel lines. If the olives are damaged or worn, use new parts for replacement.
6 SENR9973-01 Note: Put identification marks on all the fuel lines for installation purposes. Plug all the fuel lines and all the ports in the fuel filter base. This helps prevent fluid loss, and this helps to keep contaminants from entering the system. 2. Remove the fuel filter element (4). Refer to Operations and Maintenance Manual, Fuel System Filter - Replace. 3. If necessary, remove the plugs (5), the washers (6) and the inner seals (7). 4. Remove the setscrews (8) and the nuts (not shown). 5. Remove the fuel filter base (3) from the engine. Fuel Filter Base - Install i02186227 Installation Procedure Illustration 4 g01118406 1. Align the fuel filter base (3) with the mounting bracket. Install the bolts (8) and nuts (not shown). Tighten the nuts to a torque of 22 N m (16.2 lb ft). Note: Some fuel filters are installed by the OEM and torques for the mounting fasteners may vary. Check with the OEM Installation Manual for the correct torque setting. 2. If necessary, install the fuel filter element (4) to the fuel filter base (3). Refer to Operations and Maintenance Manual, Fuel System Filter - Replace. 3. If necessary, install new olives onto the fuel lines. Connect the fuel lines (1) and (2) to the fuel filter base (3). Tighten the nuts on the fuel lines (1) and (2) to a torque of 9 N m (6.6 lb ft). 4. If necessary, install new inner seals (7) to the fuel filter base (3). Install new washers (6) onto the plugs (5) and install the plugs (5) to the fuel filter base (3). Tighten the plugs (5) to a torque of 22.5 N m (16.6lbft).
SENR9973-01 7 End By: a. Remove the air from the fuel system. Refer to Operations and Maintenance Manual, Fuel System - Prime. i02801636 Fuel Injection Lines - Remove and Install Removal Procedure 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. Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened. The nozzles will be damaged if the top of the injector turns in the body. The engine will be damaged if a defective fuel injector is used because the shape of fuel (spray pattern) that comes out of the nozzle will not be correct. Note: The removal procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the 404C-22 and 404C-22T engines. Illustration 5 404C-22 and 404C-22T engines g00818680 1. Disconnect the union nuts (1) for the fuel injection lines (2) from the fuel injectors. 2. Disconnect the union nuts (1) for the fuel injection lines (2) from the fuel injection pump. 3. Remove the fuel injection lines (2) from the engine as a unit. Note: Place identification marks on all tube assemblies for installation. Plug all tube assemblies in order to prevent contamination. 4. Install suitable plastic plugs to the outlet connections of the fuel injection pump. 5. The 403C-15, 403C-17, 404C-22 and 404C-22T engines have a rigid fuel return line. For engines with a rigid fuel return line, remove the banjo bolt (4) from the fuel return line (3). Remove the washers (8) from the fuel return line (3). Discard the washers. The 402C-05, 403C-07, 403C-11 and 404C-15 engines have a flexible fuel return hose. For engines with a flexible fuel return hose, disconnect the union nut from the banjo piece.
8 SENR9973-01 Note: The installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the 404C-22 and 404C-22T engines. Illustration 6 404C-22 and 404C-22T engines g00824793 6. Remove the nut (5) from the fuel injectors (7). 7. Remove the fuel return line (3) from the engine and remove washers (6) from the fuel injectors (7). Discard the washers. 8. Install suitable plastic plugs to the fuel injectors. Installation Procedure Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened. The nozzles will be damaged if the top of the injector turns in the body. The engine will be damaged if a defective fuel injector is used because the shape of fuel (spray pattern) that comes out of the nozzle will not be correct. Illustration 7 404C-22 and 404C-22T engines g00824793 1. Remove the plastic plugs from the fuel injectors (7). Install new washers (6) to the fuel injectors (7) and install the fuel return line (3) to the fuel injectors. Note: The washers (6) have two small holes. 2. Install the nuts (5) to the fuel injectors (7). 3. The 403C-15, 403C-17, 404C-22 and 404C-22T engines have a rigid fuel return line. For engines with a rigid fuel return line, install new washers (8) to the fuel return line (3) and install the banjo bolt (4) to the fuel injection pump. Tighten the banjo bolt (4) to a torque of 7 N m (5.2 lb ft). The 402C-05, 403C-07, 403C-11 and 404C-15 engines have a flexible fuel return hose. For engines with a flexible fuel return hose, connect the fuel return hose to the banjo piece and tighten the union nut. 4. Tighten thenuts(5)toatorqueof27n m(20lbft).
SENR9973-01 9 Fuel Shutoff Solenoid - Remove and Install i02207974 Removal Procedure Illustration 8 404C-22 and 404C-22T engines g00818680 5. Remove the plastic plugs from the fuel injection lines (2) and remove the plastic plugs from the outlet connections of the fuel injection pump. Install the fuel injection lines to the engine as a unit. 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. 6. Connect the fuel injection lines (2) to the fuel injection pump. 7. Connect the fuel injection lines (2) to the fuel injectors (7). 8. For the 402C-05 and 403C-07 engines, tighten the union nuts (1) to a torque of 20 N m (15 lb ft). For the 403C-11, 403C-15,403C-17, 404C-15, 404C-22 and 404C-22T engines, tighten the union nuts (1) to a torque of 23 N m (17 lb ft). 9. Prime the fuel system. Refer to Testing and Adjusting, Fuel System - Prime for more information. Note: If new fuel injection lines have been installed, do not make any adjustments to the engine controls. Check the maximum engine speed at no load. Refer to Testing and Adjusting, Engine Speed - Check for more information. Illustration 9 g00824952 1. Disconnect electrical connections (3) to the fuel shutoff solenoid (1). Mark all connections for later installation. 2. Remove fuel shutoff solenoid (1) from the fuel injection pump housing by rotating the fuel shutoff solenoid in a counterclockwise direction. 3. Remove the O-ring (2) from fuel shutoff solenoid (1). Installation Procedure
10 SENR9973-01 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 10 g00824952 1. Check the condition of O-ring (2). If the O-ring is worn or damaged use a new part for replacement. Note: The removal procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine. 2. Install fuel shutoff solenoid (1) into the fuel injection pump housing by rotating the fuel shutoff solenoid in a clockwise direction. Tighten the fuel shutoff solenoid to a torque of 17.5 N m (12.9 lb ft). 3. Reconnect electrical connection (3) to fuel shutoff solenoid (1) before you operate the engine. i02797470 Fuel Injection Pump - Remove Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, Fuel Injection Lines - Remove and Install. b. Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, Fuel Shutoff Solenoid - Remove and Install. Illustration 11 g00825132 Illustration 12 g00825137 1. Remove the setscrews (4) and the nuts (2) that fasten the fuel injection pump to the cylinder block. Note: If the fuel rack control (5) has not been moved away from the recess of the stop solenoid, damage may occur.
SENR9973-01 11 2. Carefully raise the fuel injection pump (1) from the cylinder block and remove the clip (7) that connects the link (6) to the fuel rack control (5). 3. Remove the fuel injection pump (1) from the cylinder block. 4. Remove the shims (3) from the mounting face of the cylinder block. Note: Record the thickness of each shim and the number of shims for reassembly. The fuel injection timing is determined by the thickness of the shim pack that is between the fuel injection pump and the mounting face on the cylinder block. For more information on the fuel injection pump, refer to Specifications, Fuel Injection Pump. Illustration 13 g00825132 i02801637 Fuel Injection Pump - Install 2. Install the correct thickness and the correct number of shims (3) on the mounting face of the cylinder block. Refer to Specifications, Fuel Injection Pump. Installation Procedure Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Note: The installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine. 1. Clean the mounting face of the fuel injection pump on the cylinder block. Clean the mating surface of the fuel injection pump. Illustration 14 g00825137 3. Position the fuel injection pump (1) close to the mounting face of the cylinder block, and connect the link (6) and the fuel rack control (5) with the clip (7). 4. Put the fuel injection pump (1) in position on the mounting face of the cylinder block. 5. Install the setscrews (4) and the nuts (2) that fasten the fuel injection pump to the cylinder block. For 402C-05, 403C-07, 403C-11 and 404C-15 engines, tighten the setscrews (4) and the nuts (2) to a torqueof6n m(53lbin). For 403C-15, 403C-17, 404C-22 engines and 404C-22T engines, tighten the setscrews (4) and thenuts(2)toatorqueof15n m(11lbft).
12 SENR9973-01 End By: a. Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, Fuel Shutoff Solenoid - Remove and Install. b. Install the fuel injection lines. Refer to Disassembly and Assembly, Fuel Injection Lines - Remove and Install. Fuel Injector - Remove i02801638 Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, Fuel Injection Lines - Remove and Install. Illustration 15 g01124706 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Use a deep socket to remove the fuel injector (1) from the cylinder head. 2. Remove the seat washers (2) from the cylinder head. Discard the old seat washers. Note: 402C-05 and 403C-07 engines have two seat washers. The seat washers are different diameters. 403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and 404C-22T engines have one seat washer. 3. Cap all openings or plug all openings immediately after disassembly. Fuel Injector - Install i02801639 Installation Procedure
SENR9973-01 13 i02186260 Turbocharger - Remove and Install Removal procedure Illustration 16 g01113718 1. Clean the injector bore in the cylinder head. Ensure that no debris enters the cylinder head. Clean the threads on the body of the injector. 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. 2. Install new seat washers (3) into the injector bore in the cylinder head. Note: 402C-05 and 403C-07 engines have two seat washers. The seat washers are different diameters. 403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and 404C-22T engines have one seat washer. 3. Apply a bead of 1861117 POWERPART Universal Jointing Compound (2) to the first two threads of the injector that engage into the cylinder head. The bead of Universal Jointing Compound should haveadiameterof2mm(0.08inch)andalength of 6 mm (0.25 inch). Note: Ensure that the universal jointing compound does not cover the surface of the fuel injector body below the threads. 4. Install the fuel injector (1) into the cylinder head. Use a deep socket to tighten the fuel injector to a torque of 64 N m (47 lb ft). Note: If a new fuel injector has been installed, do not make any adjustments to the engine controls. Refer to Testing and Adjusting, Engine Speed - Check for more information. End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, Fuel Injection Lines - Remove and Install. Illustration 17 g01114005 1. Clean the outer surfaces of the turbocharger (1). 2. Loosen the hose clamps (4). Remove the air inlet hose (5).
14 SENR9973-01 9. Remove the nuts (19) and the washers (18). Remove the turbocharger (1) from the exhaust manifold. Remove the turbocharger gasket (23) from the exhaust manifold. Discard the gasket. If necessary, remove the studs (17) from the exhaust manifold. Note: Do not use the actuator rod of the wastegate to lift the turbocharger. 10. Inspect the turbocharger for damage. If the turbocharger is damaged use a new part for replacement. Refer to Testing and Adjusting, Wastegate - Test. Illustration 18 g01114003 3. Remove the exhaust pipe (not shown) from the exhaust elbow (21). Refer to the OEM provided information for the correct procedure in order to remove the exhaust pipe. 4. Remove the setscrews (15) and remove the support bracket for the turbocharger (16). Note the position of the support bracket for installation. 5. Remove the setscrews (22). Remove the exhaust elbow (21) from the turbocharger (1). Remove the gasket for the exhaust elbow (20) from the turbocharger. Discard the gasket. 11. Install suitable plastic plugs into the oil supply and into the oil drain ports of the turbocharger (1). Install suitable plastic covers to the inlet and to the outlet of the turbocharger. Install suitable plastic plugs to the oil supply tube assembly (8) and to the oil drain tube assembly (11). Installation procedure 1. Remove all of the plastic plugs from all of the ports of the turbocharger (1). Clean the mating surfaces of the exhaust manifold and the turbocharger. 6. Place a suitable container below the turbocharger (1) in order to collect any spillage of oil. 7. Remove the banjo bolt (3). Remove the oil supply tube assembly (8). Remove the washers (2) from the turbocharger. Discard the washers. If necessary, remove the setscrews (not shown) for the tube clips (6). Remove the setscrews (7). Remove the oil supply tube assembly (8) from the cylinder block. Remove the O-ring (9). Discard the O-ring. 8. Remove the setscrews (13). Remove the oil drain tube assembly (11) from the turbocharger. Remove the joint (14) and discard the joint. If necessary, remove the setscrews (12) and remove the oil drain tube assembly (11) from the cylinder block. Remove the joint (10). Discard the joint. Illustration 19 g01114003 2. Ensure that all of the turbocharger inlet and outlet ports are clean and free from restrictions. The turbocharger shaft must rotate freely.
SENR9973-01 15 3. If the studs (17) were previously removed, install the studs into the exhaust manifold. Install a new gasket (23) over the studs (17). Note: Do not use any sealant on the gasket (23). Note: Do not use the actuator rod of the wastegate to lift the turbocharger (1). 4. Position the turbocharger (1) onto the exhaust manifold. 5. Install the washers (18) and install the nuts (19). Tighten the nuts to a torque of 25 N m (18 lb ft). 6. Lubricate the bearing housing of the turbocharger (1) with clean engine oil. Apply the lubricant through the oil supply port (24). 10. Position the new washers (2) and the oil supply tube assembly (8) onto the turbocharger (1). Install the banjo bolt (3). Tighten the banjo bolt to a torque of 18 N m (13 lb ft). 11. If necessary, install a new O-ring (9) and the oil supply tube assembly (8) to the cylinder block. Install the setscrews (7). Tighten the setscrews to a torque of 10 N m (7 lb ft). 12. If necessary, install the spacer (not shown) and install the setscrews (not shown) to the tube clips (6). Torque the setscrews to 10 N m (7 lb ft). Note: Ensure that the oil supply tube assembly (8) does not come into contact with any other component when the assembly is installed onto the engine. 13. Clean the mating surfaces of the exhaust elbow (21). Position a new gasket (20) and the exhaust elbow (21) on the turbocharger (1). Install the setscrews (22). Tighten the setscrews to a torque of 32 N m (24 lbft). 14. Install the set screws (15) and install the support bracket for the turbocharger (16). Tighten the setscrews to a torque of 25 N m (18 lb ft). 15. Ensure that the inlet hose (5) is clean and free from defects or restrictions. Loosely install the hose clamps (4) to the air inlet hose (5). Install the air inlet hose to the connection of the inlet manifold and to the inlet of the turbocharger. Tighten the hose clamps. Note: Do not use oil or grease in order to install the air inlet hose. In order to install a new air inlet hose, lubricate the connection of the inlet manifold and lubricate the inlet of the turbocharger with a solution of water and 5% soap. 16. Position the exhaust pipe onto the exhaust elbow (21). Refer to the OEM information for the correct procedure in order to install the exhaust pipe. Illustration 20 g01114005 7. Clean the oil supply tube assembly (8) and the oil drain tube assembly (11). Inspect the oil supply tube assembly and the oil drain tube assembly. If necessary, replace the tube assemblies. 8. Position a new joint (14) and the oil drain tube assembly (11) onto the bottom of the turbocharger. Install the setscrews (13). Tighten the setscrews to a torque of 10 N m (7 lb ft). 9. If necessary, position a new joint (10) and the oil drain tube assembly (11) onto the cylinder block. Install the setscrews (12). Tighten the setscrews to a torque of 10 N m (7 lb ft). i02801640 Exhaust Manifold - Remove and Install Removal Procedure
16 SENR9973-01 Note: The two cylinder, the three cylinder and the four cylinder engines have different exhaust manifolds. The removal procedure is similar for all models. Illustration 22 g00825291 Illustration 21 g00825291 1. If necessary, install the exhaust manifold studs (2) to cylinder head (1). 1. Loosen the nuts (5) and the setscrews (6). Note: In order to prevent distortion of the exhaust manifold, loosen the outer fasteners first. 2. Remove the nuts (5) and the setscrews (6). Note: Identify setscrews of different lengths so thatthesetscrewscanbereinstalledinthecorrect positions. 3. Remove the exhaust manifold (4) from the cylinder head (1). 4. Remove the gasket (3) from the cylinder head. 5. Remove any remaining gasket material and carbon from the cylinder head and the exhaust manifold. Be careful not to damage the mating surface on the cylinder head or the mating surface on the exhaust manifold. 6. If necessary, remove the exhaust manifold studs (2) from the cylinder head (1). Installation Procedure 2. Install a new exhaust manifold gasket (3) to the cylinder head (1). Note: Do not use any sealant on the exhaust manifold gasket. 3. Put the exhaust manifold (4) in position on the cylinder head (1). 4. Install the nuts (5) and the setscrews (6). Note: Ensure that setscrews with different lengths are installed in the correct holes. 5. For 402C-05, 403C-07, 403C-11 and 404C-15 engines, tighten the nuts (5) and the setscrews (6) toatorqueof10n m(89lbin). For 403C-15, 403C-17, 404C-22 and 404C-22T engines, tighten the nuts (5) and the setscrews (6) to a torque of 25 N m (18 lb ft). Note: On three cylinder engines, tighten the two inner setscrews first. On four cylinder engines, tighten the four inner setscrews first. Then tighten the two outer setscrews and the two nuts. Note: The two cylinder, the three cylinder and the four cylinder engines have different exhaust manifolds. The installation procedure is similar for all models.
SENR9973-01 17 i02187986 Inlet and Exhaust Valve Springs - Remove and Install Install suitable plugs to the inlet ports of the cylinder head in order to prevent the entry of loose parts into the engine. Removal Procedure Table 1 Required Tools Part Number Part Description Qty 21825666 Valve Spring Compressor 1 27610235 Adapter 1 Start By: a. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, Rocker Shaft and Pushrod - Remove. Illustration 23 g01015085 Note: Before you begin the removal of the valve springs, refer to Specifications, Cylinder Head - Valves and Testing and Adjusting, Cylinder Head - Inspect for appropriate information on the valve springs. Note: The following procedure should be adopted in order to remove the valve springs when the cylinder head is still installed onto the cylinder block. Refer to Disassembly and Assembly, Inlet and Exhaust Valves - Remove and Install for the correct procedure that should be used to remove the valve springs from a cylinder head that has been removed from the cylinder block. Note: Ensure that the appropriate piston is at top dead center before the valve spring is removed. Failure to ensure that the piston is at top dead center may allow the valve to drop into the cylinder bore. 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. 1. Use the following procedure in order to find the top dead center position of the appropriate piston. a. Install 21825666 Valve Spring Compressor (1) and the appropriate 27610235 Adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5). b. Compress the valve spring (5) sufficiently in order to open the valve only. Do not compress the valve spring so that the valve keepers (3) could be removed from the recess in the valve stem or so that the valve stem seal (not shown) couldbedamaged. c. Slowly turn the crankshaft until the piston touches the valve. d. Continue to turn the crankshaft and release the pressure on the valve spring compressor (1) until the piston is at the top center position. Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. Note: If you are replacing all of the valve springs, on four cylinder engines only, the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or on cylinder 2 and cylinder 3. Remember that the crankshaft must not be turned while the valve springs are removed. Ensure that all of the valve springs are installed before changing from one pair of cylinders to the other pair of cylinders.
18 SENR9973-01 Do not turn the crankshaft while the valve springs are removed. 2. Use the valve spring compressor (1) and the adapter (2) in order to compress the valve spring (5). Remove the valve keepers (3). 3. Remove the valve spring retainer (4) and remove the valve spring (5). Installation Procedure Table 2 Required Tools Part Number Part Description Qty 21825666 Valve Spring Compressor 1 27610235 Adapter 1 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. Install suitable plugs to the inlet ports of the cylinder head in order to prevent the entry of loose parts into the engine. Illustration 24 g01015085 1. Place the new valve springs (5) into position on the cylinder head. 2. Install the valve spring retainer (4). 3. Install the valve spring compressor (1) and the adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5). Compress the valve spring (5). Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. 4. Install two valve keepers (3) in order to lock the valve springs in position. Do not turn the crankshaft while the valve springs are removed. 5. Carefully release the pressure on the valve spring compressor (1). Remove the valve spring compressor. 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 (3) are properly installed. Note: If you are replacing all of the valve springs, on four cylinder engines only, the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or on cylinder 2 and cylinder 3.
SENR9973-01 19 End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, Rocker Shaft and Pushrod - Install. i02187989 Inlet and Exhaust Valves - Remove and Install Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. Removal Procedure Table 3 Required Tools Part Number Part Description Qty 21825666 ValveSpringCompressor 1 27610235 Adapter 1 Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, Cylinder Head - Remove. Note: The removal procedure is identical for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine. 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. Illustration 25 g01015085 4. Install the 21825666 Valve Spring Compressor (1) and the 27610235 Adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5). Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. 5. Apply pressure to the valve spring compressor (1). Remove the valve keepers (3). 6. Slowly release the pressure on the valve spring compressor (1). 2. Place an identification mark on the heads of the valves for installation purposes. Note: The head of the inlet valve has a larger diameter than the head of the exhaust valve. 3. Position the cylinder head on a suitable surface with the valve springs facing upward. Note: Ensure that the machined face of the cylinder head is kept on a clean, soft surface in order to prevent damage to the machined surface.
20 SENR9973-01 1. Clean all parts. Ensure that all ports, all coolant passages and all lubrication passages are free from debris. To inspect the cylinder head, refer to Testing and Adjusting, Cylinder Head Inspect for further information. 2. Inspect all of the valve seats for wear and for damage. Refer to Specifications, Cylinder Head Valves and refer to Testing and Adjusting, Valve Depth - Inspect for further information. 3. Inspect all of the valve guides for wear and for damage. Refer to Specifications, Cylinder Head Valves and refer to Testing and Adjusting, Valve Guide - Inspect for further information. Illustration 26 g01113619 7. Remove the valve spring retainer (4). 8. Remove the valve spring (5). 9. Repeat steps 4 to 8 for the remaining valves. 10. Remove the valve spring compressor (1) and the adapter (2). 11. Remove the valve stem seals (6). 12. Carefully turn over the cylinder head. 13. Remove the valves (7). Illustration 27 g01113619 Installation Procedure Table 4 Required Tools Part Number Part Description Qty 21825666 Valve Spring Compressor 1 27610235 Adapter 1 Note: The installation procedure is identical for the two cylinder, the three cylinder and the four cylinder engines. The illustrations show the four cylinder engine. 4. Lubricate the stems of all valves (7) with clean engine oil. Install the valves (7) in the appropriate positions. 5. Carefully turn over the cylinder head and ensure that all of the valves remain in place. 6. Use a suitable tool to install the new valve stem seals (6) onto each of the valve guides. Note: The outer face of the valve guides must be clean and dry before installing the valve stem seals (6). The inlet valve stem and the exhaust valve stem use seals that are different parts. 7. Inspect the valve springs (5) for wear and for the correct installed length. Refer to Specifications, Cylinder Head Valves for further information. 8. Install the valve spring (5) onto the cylinder head.
SENR9973-01 21 9. Install the valve spring retainer (4). 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. 14. Remove the valve spring compressor (1) and the adapter (2) from the cylinder head. 15. 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 the valve keepers (3) are properly installed. 16. Turn over the cylinder head and check the depth of the valves below the face of the cylinder head. Refer to Specifications, Cylinder Head Valves for more information. End By: a. Install the cylinder head. Refer to Disassembly and Assembly, Cylinder Head - Install. i02801641 Engine Oil Line - Remove and Install Illustration 28 g01015303 Removal Procedure Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. 10. Install the 21825666 Valve Spring Compressor (1) and the 27610235 adapter (2) in position on the cylinder head in order to compress the appropriate valve spring (5). Ensure that the valve spring is compressed squarely or damage to the valve stem may occur. 11. Apply pressure to the valve spring compressor (1). Install the valve keepers (3). The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves. Illustration 29 g01117696 12. Carefullyreleasethepressureonthevalvespring compressor (1). 1. Loosen the nut (2) that attaches the oil line (1) to the fuel injection pump. 13. Repeat steps 8 to 12 for all of the valves.
22 SENR9973-01 2. Remove the banjo bolt (3) and remove the washers (4) from the cylinder block. Discard the washers (4). Installation Procedure Illustration 30 g01117697 3. Remove the banjo bolt (3) and remove the washers (4) from the cylinder head. Discard the washers (4). 4. Remove the oil line (1) from the engine. Illustration 31 1. Position the oil line (1) on the engine. g01117696 2. Position the banjo bolt (3) and the new washers (4) on the oil line (1). Install the oil line to the cylinder block. Illustration 32 g01117697
SENR9973-01 23 3. Position the banjo bolt (3) and the new washers (4) to the oil line (1). Install the oil line to the cylinder head. 4. Install the nut (2) that attaches the oil line (1) to the fuel injection pump. For the 402C-05, 403C-07, 403C-11 and 404C-15 engines, tighten the nut (2) to a torque of 6 N m (4.4 lb ft). For the 403C-15, 403C-17, 404C-22 and 404C-22T engines, tighten the nut (2) to a torque of 15 N m (11 lb ft). 5. Tighten the banjo bolts (3) to 11.5 N m (8.5 lb ft). i02186236 Engine Oil Cooler - Remove and Install Illustration 33 g01113679 Removal Procedure Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container. Drain the engine oil into a suitable container. Refer to the Operation and Maintenance Manual for the procedure on draining the coolant and the engine oil. 2. By using a suitable strap wrench, remove the oil filter element (5) from the oil cooler body (3). Discard the oil filter element in a suitable manner. 3. Remove the hose clamps (2) and the hoses (1) from the coolant inlet and the coolant outlet on the oil cooler body (3). Note the positions of the coolant inlet and the coolant outlet for installation. 4. Remove the adapter (4) from the oil cooler body (3). Remove the oil cooler body (3) from the cylinder block (7). 5. Remove the O-ring (6) from the oil cooler body (3). Discard the O-ring. Installation Procedure 1. Clean the mating surfaces of the oil cooler base on the cylinder block (7) and clean the oil cooler body (3). 2. Install a new O-ring (6) to the oil cooler body (3). Install the oil cooler body (3) to the cylinder block (7). 3. Install the adapter (4) through the oil cooler body (3) to the cylinder block (7). Tighten the adapter (4) to a torque of 34 N m (25 lb ft).
24 SENR9973-01 4. Install the appropriate hoses (1) to the coolant inlet and the coolant outlet on the oil cooler body (3). Tighten the hose clamps (2). 5. Lubricate the O-ring of the oil filter element (5) with clean engine oil. Install the new oil filter element to the oil cooler body (4). Tighten the oil filter element by hand. Do not useastrapwrenchtotightenthe oil filter element. 6. Fill the cooling system with coolant. Fill the lubrication system with engine oil. Refer to the Operation and Maintenance Manual, Refill Capacities for the cooling system capacity and for the lubrication system capacity of the engine. 1. Remove the engine oil relief valve (2) from the cylinder block. 2. Remove the O-ring (1) from the engine oil relief valve. Discard the O-ring. Installation Procedure Engine Oil Relief Valve - Remove and Install i02182334 Removal Procedure Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 35 g00820218 1. Install a new O-ring (1) on the engine oil relief valve (2). 2. Lubricate the engine oil relief valve (2) with clean engine oil. 3. Install the engine oil relief valve (2) in the cylinder block. Tighten the engine oil relief valve to a torque of 64 N m (47 lb ft). i02182152 Engine Oil Pump - Remove Removal Procedure Start By: a. Remove the front housing. Refer to Disassembly and Assembly, Housing (Front) - Remove. Illustration 34 g00820218
SENR9973-01 25 If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur. 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. Engine Oil Pump 3. Remove the idler gear (3) from the idler hub (1). 4. Remove the thrust washer (2) from the idler hub (1). 5. Inspect all the components for wear or damage. Any components that are worn or damaged should be replaced with new parts. Note: Refer to Specifications, Engine Oil Pump for more information. 6. If the engine oil pump has excessive buildup of sludge, inspect the oil strainer. The oil strainer can be removed by using the following procedure: a. Remove the engine oil pan. Refer to Disassembly and Assembly, Engine Oil Pan - Remove and Install. Illustration 36 g00825411 Illustration 37 g00825406 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. b. Remove the setscrews (12) and the oil strainer (13) from the cylinder block. Inspect the oil strainer for damage. If the oil strainer is damaged, use a new part for replacement. c. Remove the oil tube (11) from the cylinder block. d. Remove the O-ring (10) from the oil tube. Discard the used O-ring. 1. Remove the C-clip (9) that retains the idler gear (3) on the idler hub (1). 2. Remove the following items from the idler hub (1): Collar (8) Spring (7) Shim (6) Oil pump cover (5) Inner rotor (4)
26 SENR9973-01 Idler Hub If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur. Idler Hub Illustration 38 g00831103 1. Remove the crankshaft. Refer to Disassembly and Assembly, Crankshaft - Remove. 2. Use a hammer and use a suitable drift to remove idler hub (1) from the cylinder block (2). Align the drift to the rear face of the hub and drive the hub from the inside of the cylinder block outward. Engine Oil Pump - Install i02801642 Illustration 39 g01297224 1. Install the pin of Tooling (A) to the cylinder block. Installation Procedure Table 5 Tool Required Tools Part Number Part Description Qty A (1) 21825624 Alignment Tool 1 A (2) 21825625 Alignment Tool 1 A (3) 21825626 Alignment Tool 1 B - Multipurpose Grease 1 (1) 402C-05 and 403C-07 engines (2) 403C-11 and 404C-15 engines (3) 403C-15, 403C-17, 404C-22 and 404C-22T engines 2. Position the guide plate of Tooling (A) onto idler hub (1). Align the guide plate of Tooling (A) with pin of Tooling (A). 3. Use a hammer in order to strike the guide plate of Tooling (A). This will install idler hub (1). 4. Remove Tooling (A).
SENR9973-01 27 Engine Oil Pump Personal injury can result from the release of the spring force. The drive shaft, the piston, and the drive gear are under spring force. Use a press to slowly release the spring force before the components are removed. 4. Install the following items to idler hub (1): Oil pump cover (5) Illustration 40 g00825411 Shim (6) Spring (7) Collar (8) Refer to Illustration 40. 5. Install retaining ring (9) on idler hub (1). Illustration 41 g01297225 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 42 Checking end play by using a feeler gauge g01298012 6. Use a feeler gauge in order to measure the end play of engine oil pump. Refer to Specifications, Engine Oil Pump. 7. If the oil strainer was removed, use the following procedure for installation: 1. Apply Tooling (B) to the faces of inner rotor (4) and to the vanes of idler gear (3). 2. Align timing marks (X) on idler gear (3) with the respective timing marks on gears (14) and (15). Install idler gear (3) onto idler hub (1). 3. Install inner rotor (4) to idler gear (3).
28 SENR9973-01 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 43 a. Install a new O-ring seal (10) on oil tube assembly (11). g01037619 b. Install oil tube assembly (11) in the cylinder block. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, Refill Capacities for the approximate capacity of the cooling system. 2. Loosen the clamps and remove the hose from the water pump inlet(not shown). c. Install oil strainer (13) to the cylinder block and tighten bolts (12) to a torque of 11 N m (8 lb ft). End By: a. Install the front housing. Refer to Disassembly and Assembly, Housing (Front) - Install. b. Install the engine oil pan. Refer to Disassembly and Assembly, Engine Oil Pan - Remove and Install. Water Pump - Remove Removal Procedure (403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and 404C-22T Engines) i02801654 Illustration 44 3. Remove the fasteners (2) and the alternator bracket (1) from the water pump (3). g01124100 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.