Perkins 403d 15g руководство по эксплуатации

Disassembly and Assembly

Section

i02959949

Fuel Filter Base — Remove and Install

(403D-11, 403D-15, 403D-15T,

403D-17, 404D-15, 404D-22,

404D-22T and 404D-22TA Engines)

Removal Procedure

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Place identification marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel filter base. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

2.Loosen hose clamps (4) and disconnect hoses (5).

3.If necessary, remove fuel filter element (7) from fuel filter base (1). Refer to Operation and Maintenance Manual, “Fuel System Filter — Replace”.

4.Remove fasteners (2) and remove fuel filter base

(1) from the mounting bracket.

5.If necessary, remove plugs (6) and washers (not shown) from fuel filter base (1). Remove tube assemblies (3) and rubber olives (not shown) from fuel filter base (1).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: If the engine is equipped with a hand priming pump, the hand priming pump is mounted on the fuel filter base. The assembly of the fuel filter base and the hand priming pump is not serviceable.

1.Ensure that the fuel filter base is clean and free from damage. If necessary, replace the fuel filter base.

2.If necessary, install new rubber olives (not shown) onto tube assemblies (3). Install tube assemblies

(3)to fuel filter base (1). Ensure the correct orientation of the tube assemblies. Tighten the nuts to a torque of 9 N·m (80 lb in).

3.Install washers (not shown) onto plugs (6). Install plugs (6) to fuel filter base (1). Tighten the plugs to a torque of 23 N·m (17 lb ft).

4.Align fuel filter base (1) with the mounting bracket. Install fasteners (2). Tighten the fasteners to a torque of 50 N·m (37 lb ft).

5.If necessary, install a new fuel filter element

(7)to fuel filter base (1). Refer to Operation

and Maintenance Manual, “Fuel System Filter —

Replace”.

6. Connect hoses (5) and tighten hose clamps (4).

Note: Ensure that the hoses do not contact any other engine components.

7.Turn the fuel supply to the ON position.

8.Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System — Prime”.

i02645711

Fuel Filter Base — Remove and Install

(402D-05 and 403D-07 Engines)

Removal Procedure

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Place identification marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel filter base. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

2.Loosen hose clamps (3) and disconnect hoses (4).

3.If necessary, remove fuel filter element (5). Refer to Operations and Maintenance Manual, “Fuel System Filter — Replace”.

4.Remove bolt (1) and remove fuel filter base (2) from the mounting bracket.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Ensure that the fuel filter base is clean and free from damage. If necessary, replace the fuel filter base.

2.Align fuel filter base (2) with the mounting bracket. Install bolt (1). Tighten the bolt to a torque of

25 N·m (18 lb ft).

3.If necessary, install a new fuel filter element

(6)to fuel filter base (2). Refer to Operation

and Maintenance Manual, “Fuel System Filter —

Replace”.

4. Connect hoses (4) and tighten hose clamps (3).

Note: Ensure that the hoses do not contact any other engine components.

5.Turn the fuel supply to the ON position.

6.Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System — Prime”.

i02645722

Fuel Transfer Pump — Remove and Install

(Mechanical Fuel Transfer Pump)

Removal Procedure

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Place identification marks on all hoses for installation purposes. Plug all hoses and all the ports in the fuel transfer pump. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

Note: The fuel transfer pump can be oriented in two positions. Before removing the fuel transfer pump from the cylinder block, note the orientation of flange

(5) on fuel transfer pump (1) for assembly.

2.Loosen the hose clamps and disconnect the hoses (not shown) from fuel transfer pump (1).

3.Evenly loosen bolts (4) and remove fuel transfer pump (1) from the cylinder block.

Note: In order to remove the fuel transfer pump, it may be necessary to rotate the crankshaft until the operating plunger of the fuel transfer pump is not under pressure.

4.Remove O-ring seal (3) from fuel transfer pump

(1).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Clean the mating surfaces of the cylinder block and flange (5) on the fuel transfer pump.

Note: Ensure that the camshaft lobe for the fuel transfer pump is at minimum lift before the fuel transfer pump is installed. The fuel transfer pump can be oriented in two positions. Ensure that the fuel transfer pump is oriented in the correct position.

2.Install a new O-ring seal (3) to fuel transfer pump

(1).

3.Lubricate the operating plunger of fuel transfer pump (1) with clean engine oil.

4.Position fuel transfer pump (1) on the cylinder block. Ensure that the operating plunger is positioned correctly on the camshaft lobe. Install bolts (4). Tighten the bolts to a torque of 6 N·m (53 lb in).

5.Connect the hoses (not shown) to fuel transfer pump (1). Tighten the hose clamps.

Note: The inlet for the fuel transfer pump can be rotated 360 degrees by loosening bolt (2). The fuel inlet is adjustable in 15 degree increments. If adjustment is made to the position of the fuel inlet, tighten bolt (2) to a torque of 2.5 N·m (22 lb in).

6.Turn the fuel supply to the ON position.

7.Prime the fuel system. Refer to Systems Operation, Testing and Adjusting, “Fuel System — Prime” for additional information.

i02645719

Fuel Transfer Pump — Remove and Install

(Electrical Fuel Transfer Pump)

Removal Procedure

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

1.Turn the fuel supply to the OFF position.

2.Turn the battery disconnect switch to the OFF position.

3. Disconnect harness assembly (1).

4.Loosen hose clamps (4) and (5). Disconnect hoses (6) and (7).

5.Remove bolts (2) and remove electric transfer pump (3).

Installation Procedure

1.Ensure that the electric transfer pump is clean and free from damage. If necessary, replace the electric transfer pump.

2.Position electric transfer pump (3) on the mounting and install bolts (2).

3.Tighten bolts (2) to a torque of 9 N·m (79 lb in).

4.Connect hoses (6) and (7). Tighten hose clamps

(4) and (5).

5.Connect harness assembly (1).

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”.

i02959953

Fuel Injection Lines — Remove and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened.

The fuel injectors 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: Place identification marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination.

1. Turn the fuel supply to the OFF position.

2.Disconnect nuts (1) for fuel injection lines (2) from the fuel injectors.

3.Disconnect nuts (1) for fuel injection lines (2) from the fuel injection pump.

4.Remove fuel injection lines (2) from the engine as a unit.

5.Use suitable caps in order to plug the open ports of the fuel injection pump immediately.

6.The 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines have a rigid fuel return line.

For engines with a rigid fuel return line, remove banjo bolt (4) from fuel return line (3). Remove washers (8).

The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a flexible fuel return hose.

For engines with a flexible fuel return hose, disconnect the hose from the fuel injection pump.

7. Remove nuts (5) from fuel injectors (7).

Note: For engines with a rigid fuel return line, ensure that the fuel return line is not distorted when the nuts are loosened.

8.Remove fuel return line (3) and washers (6) from fuel injectors (7).

9.Use suitable caps in order to plug the fuel injectors immediately.

Installation Procedure

Table 1

Required Tools

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened.

The fuel injectors 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 installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines.

The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a flexible fuel return hose.

For engines with a flexible fuel return hose, connect the fuel return hose to the fuel injection pump.

4. Tighten nuts (5) to a torque of 27 N·m (20 lb ft).

1.Remove the caps from fuel injectors (7). Install new washers (6) and fuel return line (3) to fuel injectors (7).

Note: The washers (6) have two small holes.

2.Install nuts (5) to fuel injectors (7).

3.The 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22TA and 404D-22TA engines have a rigid fuel return line.

For engines with a rigid fuel return line, install new washers (8) to fuel return line (3) and install banjo bolt (4) to the fuel injection pump. Tighten banjo bolt (4) to a torque of 7 N·m (62 lb in).

5.Remove the caps from the outlet connections of the fuel injection pump. Install the fuel injection lines to the engine as a unit.

6.Connect fuel injection lines (2) to fuel injectors (7). Tighten the union nuts (1) finger tight.

7.Use Tooling (A) to tighten union nuts (1) at the fuel injection pump.

For 402D-05 and 403D-07 engines, tighten union nuts (1) to a torque of 20 N·m (15 lb ft).

For 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines, tighten the union nuts (1) to a torque of 23 N·m (17 lb ft).

Note: For the three cylinder and the four cylinder engines, tighten the center union nuts first.

8.Use Tooling (A) to tighten union nuts (1) at the fuel injections.

For 402D-05 and 403D-07 engines, tighten union nuts (1) to a torque of 20 N·m (15 lb ft).

For 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines, tighten the union nuts (1) to a torque of 23 N·m (17 lb ft).

9.Turn the fuel supply to the ON position.

10.Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System — Prime” for more information.

2.Disconnect electrical connection (3) from the harness assembly (not shown). Mark all connections for installation.

3.Remove fuel shutoff solenoid (1) from the fuel injection pump housing by rotating the fuel shutoff solenoid in a counterclockwise direction.

4.Remove sealing washer (2) from fuel shutoff solenoid (1).

Fuel Shutoff Solenoid —

Remove and Install

i02645718 Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Removal Procedure

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Turn the battery disconnect switch to the OFF position.

1.Install sealing washer (2) to fuel shutoff solenoid

(1).

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 N·m (12 lb ft).

3.Connect electrical connection (3) to the harness assembly (not shown).

4.Turn the battery disconnect switch to the ON position.

i02959957

Fuel Injection Pump — Remove and Install

Removal Procedure

Start By:

a.Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, “Fuel Shutoff Solenoid — Remove and Install”.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The removal procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The Illustrations show a four cylinder engine.

1.Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines — Remove and Install” for more information.

The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a flexible fuel return hose.

For engines with a flexible fuel return hose, disconnect the fuel hose from the inlet connection of the fuel injection pump.

2.Gradually loosen bolts (4) and nuts (2) that fasten the fuel injection pump to the cylinder block.

3.Carefully raise fuel injection pump (1) from the cylinder block and remove clip (7) that connects link (6) to fuel rack control (5).

4.Remove fuel injection pump (1) from the cylinder block.

5.Remove 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. Refer

to Specifications, “Fuel Injection Pump” for more information.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. The Illustrations show a four cylinder engine.

1.Clean the mating surfaces of the cylinder block and the fuel injection pump.

2.New shims (3) must be used during assembly. Install the correct thickness and the correct number of shims on the mounting face of the cylinder block. Refer to Specifications, “Fuel Injection Pump” for more information.

3.Position fuel injection pump (1) close to the mounting face of the cylinder block, and connect link (6) and fuel rack control (5) with clip (7).

4.Align fuel injection pump (1) with the studs on the cylinder block. Install the fuel injection pump to the cylinder block.

5.Install bolts (4) and nuts (2). Ensure that the tube clip for the engine oil line is secured by the appropriate fastener.

For 402D-05, 403D-07, 403D-11 and 404D-15 engines, evenly tighten bolts (4) and nuts (2) to a torque of 6 N·m (53 lb in).

For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, evenly tighten bolts (4) and nuts (2) to a torque of 15 N·m

(11 lb ft).

6.Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines — Remove and Install”.

The 402D-05, 403D-07, 403D-11 and 404D-15 engines have a flexible fuel return hose.

For engines with a flexible fuel return hose, connect the fuel hose to the inlet connection of the fuel injection pump.

End By:

a.Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, “Fuel Shutoff Solenoid — Remove and Install”.

i02959963

Fuel Injector — Remove and Install

Removal Procedure

Start By:

a.Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines — Remove and Install”.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Use a deep socket to remove fuel injector (1) from the cylinder head.

2.Remove seat washers (2) from the cylinder head.

Note: 402D-05 and 403D-07 engines have two seat washers. The seat washers are different diameters. The 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines have one seat washer.

3. Cap all openings or plug all openings immediately.

Installation Procedure

Table 2

Required Tools

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened 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.

2.Install new seat washers (2) into the bore for the fuel injector in the cylinder head.

g01320610

Note: 402D-05 and 403D-07 engines have two seat washers. The seat washers are different diameters. The 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines have one seat washer.

3.Apply a bead of Tooling (A) to the first two threads of the fuel injector that engage into the cylinder head. The bead should have a diameter of 2 mm (0.08 inch) and a length of 6 mm (0.25 inch).

Note: Ensure that Tooling (A) does not cover the body of the fuel injector below the threads.

4.Install 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).

End By:

a.Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines — Remove and Install”.

i02645771

Turbocharger — Remove and Install

Removal procedure

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Plug and cap all open ports and tube assemblies.

1.Loosen hose clamps (5) and remove air inlet hose

(1).

2.Remove allen head screws (21) and remove exhaust elbow (19) from turbocharger (4). Remove gasket (18) from the turbocharger.

3.Remove banjo bolt (2) and washers (3). Remove the fasteners and the spacers (not shown) for tube clips (6). Remove bolts (14) and remove tube assembly (13) from the cylinder block. Remove O-ring seal (12).

4.Remove bolts (8) and disconnect tube assembly (10) from the turbocharger. Remove joint (7).

If necessary, remove bolts (9) and remove tube assembly (10) from the cylinder block. Remove joint (11).

5.Remove nuts (17) and remove turbocharger (4) from the exhaust manifold. Remove gasket (20) from the exhaust manifold. If necessary, remove studs (15) from the exhaust manifold.

Note: Do not use the actuator rod of the wastegate to lift the turbocharger.

Installation procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. If the turbocharger is worn, the complete turbocharger must be replaced.

2.Test the actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, “Wastegate — Test” for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.

5.Ensure that tube assemblies (10) and (13) are clean and free from damage. If necessary, replace the tube assemblies.

6.If necessary, position a new joint (11) and tube assembly (10) onto the cylinder block. Install bolts

(9). Tighten the bolts finger tight.

i02959965

Exhaust Manifold — Remove and Install

Position a new joint (7) on tube assembly (10). Align tube assembly (10) to the bottom of the turbocharger. Install bolts (8). Tighten the bolts finger tight.

Tighten bolts (8) and (9) to a torque of 10 N·m (89 lb in).

7.Lubricate the bearings of turbocharger (4) with clean engine oil through oil inlet port (16). Rotate the shaft of the turbocharger in order to distribute the lubricant.

8.Install a new O-ring seal (12) to tube assembly (13). Position tube assembly (13) against the cylinder block. Install bolts (14). Tighten the bolts to a torque of 10 N·m (89 lb in).

9.Install new washers (3) and banjo bolt (2) to tube assembly (13). Position tube assembly (13) onto turbocharger (4). Tighten the banjo bolt finger tight.

10.If necessary, install the spacer and install the fasteners (not shown) to tube clips (6). Torque the fasteners to 10 N·m (89 lb in).

11.Tighten banjo bolt (2) to a torque of 18 N·m

(13 lb ft).

Note: Ensure that the tube assembly does not come into contact with any other components.

12.Clean the mating surfaces of exhaust elbow (19). Position a new gasket (18) and exhaust elbow (19) on turbocharger (4). Install allen head screws (21). Tighten the bolts to a torque of 32 N·m (24 lb ft).

13.Ensure that inlet hose (1) is clean and free from defects or restrictions. Loosely install hose clamps

(5) to air inlet hose (1). Install the air inlet hose to the connection of the inlet manifold (not shown) and to the turbocharger. Tighten the hose clamps.

Removal Procedure

Start By:

a.If the engine is equipped with a turbocharger, remove the turbocharger. Refer to Disassembly and Assembly, “ Turbocharger, Remove and Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The two cylinder, the three cylinder and the four cylinder engines have different exhaust manifolds. The removal procedure is similar for all models.

1. Loosen nuts (5) and bolts (6).

Note: In order to prevent distortion of the exhaust manifold, loosen the outer fasteners first.

2. Remove nuts (5) and bolts (6).

Note: Identify bolts of different lengths so that the bolts can be installed in the correct positions.

3.Remove exhaust manifold (4) from cylinder head

(1). Note the orientation of the exhaust manifold for installation.

4.Remove gasket (3) from cylinder head (1).

5.If necessary, remove exhaust manifold studs (2) from cylinder head (1).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The two cylinder, the three cylinder and the four cylinder engines have different exhaust manifolds. The installation procedure is similar for all models.

1.Ensure that the mating surfaces of the cylinder head and the exhaust manifold are clean and free from damage.

2.If necessary, install exhaust manifold studs (2) to cylinder head (1).

3.Install a new exhaust manifold gasket (3) to cylinder head (1).

4.Align exhaust manifold (4) with studs (2) and install the exhaust manifold to cylinder head (1).

Note: Ensure that the exhaust manifold is installed in the correct orientation.

5. Install nuts (5) and bolts (6) finger tight.

Note: Ensure that bolts of different lengths are installed in the correct positions.

6.For 402D-05, 403D-07, 403D-11, 403D-15, 403D-15T, 403D-17, and 404D-15 engines, tighten nuts (5) and bolts (6) to a torque of 10 N·m (89 lb in).

For 404D-22, 404D-22T and 404D-22TA engines, tighten nuts (5) and bolts (6) to a torque of 25 N·m (18 lb ft).

Note: On three cylinder engines and four cylinder engines, tighten the inner bolts first.

End By:

a.If the engine is equipped with a turbocharger, install the turbocharger. Refer to Disassembly and Assembly, “ Turbocharger, Remove and Install”.

i02959972

Inlet and Exhaust Valve Springs — Remove and Install

Removal Procedure

Table 3

Required Tools

(1)402D-05 and 403D-07 engines

(2)403D-11 and 404D-15 engines

(3)403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines

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

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Install suitable plugs to the inlet ports of the cylinder head in order to prevent the entry of loose parts into the engine.

NOTICE

Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.

Note: The removal procedure is similar for the two cylinder, the three cylinder and the four cylinder engines. 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.

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.

2.Use tool (A) in order to compress valve spring (3). Remove valve keepers (1).

Note: For four cylinder engines, 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.

NOTICE

Do not turn the crankshaft while the valve springs are removed.

3.Apply sufficient pressure to Tooling (A) in order to allow removal of the valve keepers (1).

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

Remove valve keepers (1).

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

5.Remove valve spring retainer (2) and remove valve spring (3).

6.Remove Tooling (A) and (B).

Installation Procedure

Table 4

Required Tools

(1)402D-05 and 403D-07 engines

(2)403D-11 and 404D-15 engines

(3)403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Do not turn the crankshaft while the valve springs are removed.

NOTICE

Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.

NOTICE

Install suitable plugs to the inlet ports of the cylinder head in order to prevent the entry of loose parts into the engine.

1.Inspect the valve springs for the correct length. Refer to Specifications, “Cylinder Head Valves ”.

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.

NOTICE

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

3.Install Tooling (A) and (B) in the appropriate position on the cylinder head in order to compress the valve spring.

4.Apply sufficient pressure to Tooling (A) in order to install valve keepers (1).

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.

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.

End By:

a.Install the rocker shaft assembly. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrod — Install”.

i02959973

Inlet and Exhaust Valves — Remove and Install

Removal Procedure

Table 5

Required Tools

Start By:

a.Remove the cylinder head. Refer to Disassembly and Assembly, “Cylinder Head — Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The removal procedure is identical for the two cylinder, the three cylinder and the four cylinder engines. The Illustrations show a 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.

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.

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

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

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).

6.Remove valve (5).

7.Remove valve stem seal (4).

8.Repeat Steps 3 to 7 for the remaining valves.

Installation Procedure

Table 6

Required Tools

(1)402D-05 and 403D-07 engines

(2)403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA engines

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The installation procedure is identical for the two cylinder, the three cylinder and the four cylinder engines. The Illustrations show a four cylinder engine.

1.Clean all components of the cylinder head assembly. Ensure that all ports, all coolant passages and all lubrication passages in the cylinder head are free from debris. Follow Steps 1.a through 1.e in order to inspect the components of the cylinder head assembly. Replace any components that are worn or damaged.

a.Inspect the cylinder head for wear and for damage. Refer to Systems Operation, Testing and Adjusting, “Cylinder Head Inspect”.

b.Inspect the valve seats for wear and for damage. Refer to Specifications, “Cylinder Head Valves” for further information.

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”.

2.Use Tooling (B) to install new valve stem seals (4) onto each of the valve guides.

Note: The outer face of the valve guides must be clean and dry before installing the valve stem seals.

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).

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

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

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 4 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. Refer to Disassembly and Assembly, “Cylinder Head — Install”.

i02959976

Engine Oil Line — Remove and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

1.Loosen nut (2) that attaches the clip on oil line (1) to the fuel injection pump.

2.Remove banjo bolt (3) and remove washers (4) from the cylinder block.

3.Remove banjo bolt (5) and remove washers (6) from the cylinder head.

1.Place oil line (1) on the engine. Ensure that the clip on the oil line is located below nut (2).

2.Position banjo bolt (3) and new washers (4) onto oil line (1). Install the banjo bolt and oil line to the cylinder block finger tight.

3.Position banjo bolt (5) and new washers (6) onto oil line (1). Install the banjo bolt and the oil line to the cylinder head finger tight.

4.Tighten nut (2) that attaches the clip on oil line (1) to the fuel injection pump.

For 402D-05, 403D-07, 403D-11 and 404D-15 engines, tighten nut (2) to a torque of 6 N·m (53 lb in).

For 403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines, tighten nut (2) to a torque of 15 N·m (133 lb in).

5.Tighten banjo bolts (3) and (5) to a torque of 12 N·m (106 lb in).

i02645673

Engine Oil Cooler — Remove and Install

Removal Procedure

Table 7

Required Tools

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Drain the coolant from the cooling system into a suitable container. Refer to Operation and Maintenance Manual, “Cooling System Coolant — Drain” for the correct procedure.

2.Drain the engine lubricating oil into a suitable container. Refer to Operation and Maintenance Manual, “Engine Oil and Filter — Change” for the correct procedure.

3.Use Tooling (A) to remove oil filter element (5).

4.Loosen hose clamps (2) and disconnect hoses

(1). Note the positions of the coolant inlet and the coolant outlet for installation.

5.Remove adapter (4) and remove oil cooler (3) from the cylinder block.

Note: Make a temporary mark in order to show the orientation of the oil cooler for installation.

6. Remove O-ring seal (6) from oil cooler (3).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Ensure that the oil cooler is clean and free from damage. Clean the mating surfaces of the cylinder block.

i02645679

Engine Oil Relief Valve — Remove and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

2.Install a new O-ring seal (6) to oil cooler (3). Position oil cooler (3) on the cylinder block and install adapter (4). Tighten adapter (4) to a torque of 34 N·m (25 lb ft).

Note: Ensure that the oil cooler is correctly oriented.

3.Connect hoses (1) to the coolant inlet and the coolant outlet on oil cooler (3). Tighten hose clamps (2).

4.Install a new oil filter element (5).

5.Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, “Cooling System Coolant — Fill” for the correct procedure.

6.Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, “Engine Oil Filter — Change” for the correct procedure.

1.Remove engine oil relief valve (2) from the cylinder block.

2.Remove O-ring seal (1) from engine oil relief valve

(2).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Removal Procedure

Start By:

a.Remove the front housing. Refer to Disassembly and Assembly, “Housing (Front) — Remove”.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur.

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.Remove C-clip (9) that retains idler gear (3) on idler hub (1).

2.Remove the following items from idler hub (1):

•Collar (8)

•Spring (7)

•Shim (6)

•Oil pump cover (5)

3.Remove idler gear (3) from idler hub (1).

4.Remove inner rotor (4) from idler hub (1).

5.Remove thrust washer (2) from idler hub (1).

6.In order to remove the suction pipe, follow Steps 6.a through 6.d .

Idler Hub

1.Remove camshaft (16). Refer to Disassembly and Assembly, “Camshaft — Remove”.

2.Remove bolts (17) and plate (14) from the cylinder block. Remove joint (15).

3.Remove crankshaft (18). Refer to Disassembly and Assembly, “Crankshaft — Remove”.

a.Remove the engine oil pan. Refer to Disassembly and Assembly, “Engine Oil Pan — Remove and Install”.

b.Remove bolts (12) and 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 suction pipe (11) from the cylinder block.

d.Remove O-ring seal (10) from the suction pipe.

4.Use a hammer and use a suitable drift to remove idler hub (1) from the cylinder block. Align the drift to the rear face of the hub and drive the hub from the inside of the cylinder block outward.

i02960005

Engine Oil Pump — Install

Installation Procedure

Table 8

Required Tools

(1)402D-05 and 403D-07 engines

(2)403D-11 and 404D-15 engines

(3)403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA engines

3.Use a hammer in order to strike the guide plate of Tooling (A). Drive idler hub (1) into the cylinder block until the guide plate contacts the front of the cylinder block.

4.Remove Tooling (A).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur.

5.Install crankshaft (18). Refer to Disassembly and Assembly, “Crankshaft — Install”.

6.Position a new joint (15) on the cylinder block. Align plate (14) with the dowels in the cylinder block and install the plate. Install bolts (17) and tighten to a torque of 10 N·m (89 lb in).

7.Install camshaft (18). Refer to Disassembly and Assembly, “Camshaft — Install”.

Idler Hub

1.Install the pin of Tooling (A) to the cylinder block.

2.Install idler hub (1) into the guide plate of Tooling

(A). Align the guide plate of Tooling (A) with pin of Tooling (A).

Engine Oil Pump

1.Install thrust washer (2). Lubricate the thrust washer with clean engine oil.

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.

2.Apply Tooling (B) to the faces of inner rotor (4) and to the vanes of idler gear (3).

3.Align timing marks (X) on idler gear (3) with the respective timing marks on gears (19) and (20). Install idler gear (3) onto idler hub (1).

4.Install inner rotor (4) to idler gear (3).

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.

5.Install the following items to idler hub (1):

•Oil pump cover (5)

•Shim (6)

•Spring (7)

• Collar (8)

Refer to Illustration 48.

6. Install retaining ring (9) on idler hub (1).

7.Use a feeler gauge in order to measure the end play of the engine oil pump. Refer to Specifications, “Engine Oil Pump”.

8.If the oil strainer was removed, follow Steps 8.a through 8.c in order to install the oil strainer.

a.Install a new O-ring seal (10) on oil tube assembly (11).

b.Install oil suction pipe (11) in the cylinder block.

c.Install oil strainer (13) to the cylinder block and tighten bolts (12) to a torque of 11 N·m (97 lb in).

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”.

i02960013

Water Pump — Remove and Install

(403D-11, 403D-15, 403D-15T,

403D-17, 404D-15, 404D-22,

404D-22T and 404D-22TA Engines)

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”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

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

Dispose of all fluids according to local regulations and mandates.

1.Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant — Drain” for more information.

2.Loosen the hose clamp and disconnect the hose (not shown) from the water pump inlet.

3.Loosen hose clamps (5) and remove hose (6) from water pump (1).

4.Remove bolt (3) and alternator bracket (2) from water pump (1).

Note: The alternator bracket on some engines is secured by two bolts.

5. Remove fasteners (7) and remove water pump (1).

Note: If necessary, gently tap the water pump with a soft faced hammer in order to loosen the water pump.

6. Remove joint (4) from the cylinder block.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1.Ensure that the mating surfaces of the water pump and the cylinder block are clean and free from damage.

2.Install a new joint (4) to the cylinder block.

3.Place water pump (1) in position and install fasteners (7) finger tight.

4.Position alternator bracket (2) on the water pump. Install bolt (3) finger tight.

Note: The alternator bracket on some engines is secured by two bolts.

5.For engines that have an alternator bracket that is secured by one bolt, tighten fasteners (7) to a torque of 10 N·m (89 lb in).

For engines that have an alternator bracket that is secured by two bolts, tighten fasteners (3) and (7) to a torque of 10 N·m (89 lb in).

6.Connect the hose (not shown) to the water pump inlet and tighten the hose clamp. Install hose (6) on the water pump and tighten hose clamps (5).

7.Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant — Fill” for the correct procedure.

End By:

a.Install the alternator. Refer to Disassembly and Assembly, “Alternator — Remove and Install”.

b.Install the fan. Refer to Disassembly and Assembly, “Fan — Remove and Install”.

i02645778

Water Pump — Remove and Install

(402D-05 and 403D-07 Engines)

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”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.