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Products
Perkins 1600 Engine Maintenance Disassembly Assembly Manual


Detailed Description:

Disassembly and

Assembly

1600 Series Industrial Engine

XGA (Engine)

XGB (Engine)

XGD (Engine)

XGE (Engine)

XGF (Engine)

XGH (Engine)

This document is printed from SPI². Not for RESALE


Important Safety Information

Most accidents tha t involve produc t op eration, ma intena nc e and repair are caus ed by failure to

ob serve basic safety rules or precautions. An accident can often be avoided by recog nizing pote ntially

ha za rdous situations before an accident oc curs. A person mus t be alert to pote ntial ha za rds. This

person should also ha ve the ne cessary training, skills and tools to perform the se func tions 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.

Sa fety precautions and warning s are provided in this ma nua l and on the produc t. If the se ha za rd

warning s are not he eded, bod ily injury or death could oc cur to you or to othe r persons.

The ha za rds are identified by the “Safety Alert Symb ol” and followed by a “Signa l Word” suc h as

"DANGER", "WARNING" or "CAUTION". The Sa fety Alert "WARNING" label is shown below.

The me aning of this safety alert symb ol is as follows:

Attention! Become Alert! Your Safety is Involved.

The me ssage tha t appears und er the warning explains the ha za rd and can be either written or

pictorially presente d.

Op erations tha t ma y caus e produc t dama ge are identified by “NOTICE” labels on the produc t and in

this pub lication.

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 informa tion, specifications, and illustrations in this pub lication are on the basis of informa tion tha t

was available at the time tha t the pub lication was written. The specifications, torque s, pressure s,

me asure me nts, adjustme nts, illustrations, and othe r items can cha ng e at any time. These cha ng es can

affect the service tha t is given to the produc t. Ob tain the comp lete and mos t current informa tion before

you start any job. Pe rkins dealers or Pe rkins distributors ha ve the mos t current informa tion available.

When replacement parts are required for this

product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE


KENR8773

3

Table of Contents

Table of Contents

Inlet and Exhaust Valve Springs-Remove and Install

(1606A and 1606D Engines) ............... 67

Inlet and Exhaust Valves-Remove and Install

(1606A and 1606D Engines) ............... 70

Inlet and Exhaust Valve Guides-Remove and Install

(1606A and 1606D Engines) ............... 72

Engine Centrifugal Oil Filter-Remove and Install

(1606D Engines) .............................. ... 74

Engine Oil Filter Base-Remove (1606A and 1606D

Engines) ... .............. 77

Engine Oil Filter Base-Disassemble (1606A and

1606D Engines) ............... ... 79

Engine Oil Filter Base-Assemble (1606A and 1606D

Engines) ... .............. 80

Engine Oil Filter Base-Install (1606A and 1606D

Engines) ... .............. 82

Engine Oil Cooler-Remove (1606A and 1606D

Engines) ... .............. 84

Engine Oil Cooler-Install (1606A and 1606D

Engines) ... .............. 85

Engine Oil Temperature Regulator-Remove and

Install (1606A and 1606D Engines) ..... 86

Engine Oil Relief Valve-Remove and Install (1606A

and 1606D Engines) ................. 87

Engine Oil Pump-Remove (1606A and 1606D

Engines) ... .............. 88

Engine Oil Pump-Install (1606A and 1606D

Disassembly and Assembly Section

Fuel Filter Base-Remove (1606A and 1606D

Engines) ... ... 5

Fuel Filter Base-Disassemble (1606A and 1606D

Engines) ... ... 6

Fuel Filter Base-Assemble (1606A and 1606D

Engines) ... ................ 8

Fuel Filter Base-Install (1606A and 1606D

engines) ................................... .............. 10

Switch (Water in Fuel)-Remove and Install (1606A

and 1606D Engines) ........................... 12

Fuel Transfer Pump-Remove (1606A and 1606D

Engines) ... .............. 12

Fuel Transfer Pump-Install (1606A and 1606D

Engines) ... .............. 14

Exhaust Gas Recirculation Cooler-Remove and

Install (1606D Engines) ..................... 16

Electronic Unit Injector-Remove (1606A and 1606D

Engines) ... .............. 18

Electronic Unit Injector-Install (1606A and 1606D

Engines) ... .............. 19

Electronic Unit Injector Sleeve-Remove (1606A and

1606D Engines) ............... ... twenty one

Electronic Unit Injector Sleeve-Install (1606A and

1606D Engines) ............... ... twenty two

Injection Actuation Pressure Control Valve-Remove

and Install (Injection Pressure Regulator (IPR) Valve

for 1606A and 1606D Engines) ........... 23

Injection Actuation Pressure Control Sensor

Engines) ... .............. 90

Water Pump-Remove (1606A and 1606D

Engines) ... .............. 92

Water Pump-Install (1606A and 1606D

Engines) ... .............. 93

Water Temperature Regulator Housing-Remove and

Install (1606A and 1606D Engines) ........... 94

Engine Support (Front)-Remove and Install (1606A

and 1606D Engines) ........................... 95

Flywheel-Remove (1606A and 1606D Engines): 96

Flywheel-Install (1606A and 1606D Engines) ..... 97

Crankshaft Rear Seal-Remove (1606A and 1606D

Engines) ... .............. 99

Crankshaft Rear Seal-Install (1606A and 1606D

Engines) ... ............ 100

Flywheel Housing-Remove and Install (1606A and

1606D Engines) ............... . 101

Vibration Damper and Pulley-Remove and Install

(1606A and 1606D Engines) .............. 104

Crankshaft Front Seal-Remove (1606A and 1606D

Engines) ... ............ 107

Crankshaft Front Seal-Install (1606A and 1606D

Engines) ... ............ 108

Front Cover-Remove (1606A and 1606D

-Remove and Install (1606A and 1606D

Engines) ... .............. twenty four

Unit Injector Hydraulic Pump-Remove and Install

(1606A and 1606D Engines) ............... 25

Unit Injector Hydraulic Pump Gear-Remove and

Install (1606A and 1606D Engines) ..... 30

Unit Injector Actuation Oil Manifold-Remove and

Install (1606A and 1606D Engines) ..... 31

Air Cleaner-Remove and Install (1606A and 1606D

Engines) ... .............. 36

Turbocharger-Remove (1606D Engines) ............ 38

Turbocharger-Remove (1606A Engines) ............ 39

Turbocharger-Install (1606D Engines) ... 40

Turbocharger-Install (1606A Engines) ... 42

Exhaust Gas Recirculation Valve-Remove and

Install (1606D Engines) .............. 44

Exhaust Manifold-Remove (1600D Engines) ... 47

Exhaust Manifold-Remove (1606A Engines) ... 50

Exhaust Manifold-Install (1600D Engines) ..... 52

Exhaust Manifold-Install (1606A Engines) .......... 56

Pressure Sensor (Exhaust Manifold)-Remove and

Install (1600D Engine) ........................ 59

Exhaust Elbow-Remove and Install (1606A and

1606D Engines) ............... ... 61

Air Inlet Heater-Remove and Install (1606A and

1606D Engines) ............... ... 61

Inlet Manifold-Remove and Install (1606A and

1606D Engines) ............... ... 63

Engines) ... ............. 110

Front Cover-Install (1606A and 1606D

Engines) ... ............. 113

Gear Group (Front)-Remove (1606A and 1606D

Engines) ... ............. 117

Gear Group (Front)-Install (1606A and 1606D

Engines) ... ............. 118

Housing (Front)-Remove (1606A and 1606D

Engines) ... ............. 119

Housing (Front)-Install (1606A and 1606D

Engines) ... ............ 122

This document is printed from SPI². Not for RESALE


4

KENR8773

Table of Contents

Crankcase Breather-Remove and Install (1606A

and 1606D Engines) ...

Valve Mechanism Cover-Remove and Install (1606A

and 1606D Engines) ...

Rocker Shaft and Pushrod-Remove (1606A and

1606D Engines) ............... . 136

Rocker Shaft-Disassemble (1606A and 1606D

Engines) ... ............ 137

Rocker Shaft-Assemble (1606A and 1606D

Engines) ... ............ 138

Rocker Shaft and Pushrod-Install (1606A and

1606D Engines) ............... . 139

Cylinder Head-Remove (1606A and 1606D

Engine Oil Pressure Sensor-Remove and Install

(1606A and 1606D Engines) .............. 189

Engine Oil Temperature Sensor-Remove and Install

(1606A and 1606D Engines) .............. 190

Fuel Pressure Sensor-Remove and Install (1606A

and 1606D Engines) ...

Inlet Manifold Temperature Sensor-Remove and

Install (1606A and 1606D Engines) ........ 193

Inlet Manifold Pressure Sensor-Remove and Install

(1606A and 1606D Engines) ...

Jacket Water Heater-Remove and Install (1606A

and 1606D Engines) ............... 195

Alternator Belt-Remove and Install (1606A and

1606D Engines) ............... . 196

Belt Tensioner-Remove and Install (1606A and

1606D Engines) ............... . 197

Fan-Remove and Install (1606A and 1606D

Engines) ... ............ 141

Cylinder Head-Install (1606A and 1606D

Engines) ... ............ 144

Lifter Group-Remove (1606A and 1606D

Engines) ... ............ 147

Lifter Group-Install (1606A and 1606D

Engines) ... ............ 148

Camshaft-Remove (1606A and 1606D

Engines) ... ............ 148

Camshaft-Install (1606A and 1606D Engines): 150

Camshaft Gear-Remove and Install (1606A and

1606D Engines) ............... . 152

Camshaft Bearings-Remove and Install (1606A and

1606D Engines) ............... . 153

Engine Oil Pan-Remove and Install (1606A and

1606D Engines) ............... . 155

Cylinder Liner-Remove (1606A and 1606D

engines) ................................... ............ 198

Fan Drive-Remove and Install (1606A and 1606D

Engines) ... ............ 199

Electronic Control Module-Remove and Install

(1606A and 1606D Engines) ............... 201

Alternator-Remove and Install (1606A and 1606D

Engines) ... ............ 204

Electric Starting Motor-Remove and Install (1606A

and 1606D Engines) ...

Index Section

Index ............................. .................. 207

Engines) ... ............ 159

Cylinder Liner-Install (1606A and 1606D

Engines) ... ............ 160

Piston Cooling Jets-Remove and Install (1606A and

1606D Engines) ............... . 162

Pistons and Connecting Rods-Remove (1606A and

1606D Engines) ............... . 163

Pistons and Connecting Rods-Disassemble (1606A

and 1606D Engines) ...

Pistons and Connecting Rods-Assemble (1606A

and 1606D Engines) ...

Pistons and Connecting Rods-Install (1606A and

1606D Engines) ............... . 168

Crankshaft Main Bearings-Remove (1606A and

1606D Engines with Crankshaft in Position) ..... 170

Crankshaft Main Bearings-Install (1606A and 1606D

Engines with Crankshaft in Position) ... 171

Crankshaft-Remove (1606A and 1606D

Engines) ... ............ 174

Crankshaft-Install (1606A and 1606D

Engines) ... ............ 176

Crankshaft Timing Ring-Remove and Install (1606A

and 1606D Engines) ............... 181

Crankshaft Gear-Remove and Install (1606A and

1606D Engines) ............... . 182

Bearing Clearance-Check ...

Camshaft Position Sensor-Remove and Install

(1606A and 1606D Engines) .............. 185

Crankshaft Position Sensor-Remove and Install

(1606A and 1606D Engines) ...

Coolant Temperature Sensor-Remove and Install

(1606A and 1606D Engines) .............. 187

This document is printed from SPI². Not for RESALE


KENR8773

5

Disassembly and Assembly Section

Disassembly and Assembly

Section

i04638569

Fuel Filter Base-Remove

(1606A and 1606D Engines)

Removal Procedure

Table 1

Required Tools

Tool

Part Number

Part Description

Capping Kit

Qty

A

29990075

1

g02797418

NOTICE

Illustration 1

Ensure that all adjustments and repairs that are

carried out to the fuel system are performed by

authorized personnel that have the correct train-

ing.

3. If necessary, disconnect hose assembly from inlet

connection (2).

4. Drain the fuel from fuel fi lter base (1). Refer to

the Operation and Maintenance Manual, "Fuel

System Primary Filter / Water Separator-Drain ”for

the correct procedure.

Before beginning ANY work on the fuel system, re-

fer to Operation and Maintenance Manual, “Gen-

eral Hazard Information and High Pressure Fuel

Lines ”for safety information.

5. Disconnect the fuel hose assembly from inlet

connection (3) on fuel fi lter base (1).

Refer to System Operation, Testing and Adjusting,

"Cleanliness of Fuel System Components" for de-

tailed information on the standards of cleanliness

that must be observed during ALL work on the fu-

el system.

6. Use Tooling (A) in order to plug the fuel hose

assembly. Use Tooling (A) in order to cap

connection (3).

7. Disconnect fuel hose assembly from return

connection (10) on fuel fi lter base (1).

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF

position.

8. Use Tooling (A) in order to plug the fuel hose

assembly. Use Tooling (A) in order to cap

connection (10).

9. Disconnect harness assembly (6) from water in

fuel sensor (7) (not shown).

10. Disconnect harness assembly (8) from fuel

pressure sensor (9).

11. Remove nut (4) and disconnect harness assembly

(5) from the stud bolt on fuel fi lter base (1).

This document is printed from SPI². Not for RESALE


6

Disassembly and Assembly Section

KENR8773

g03158102

g03158357

Illustration 2

Illustration 3

12. Disconnect tube assembly (11) from fuel fi lter

base (1) and fuel transfer pump (14).

22. Remove bolt (18) and stud bolts (19) from fuel

fi lter base (1). Support the fuel fi lter base as the

bolts are removed.

13. Remove O-ring seal (12) (not shown) from the

connection on fuel fi lter base (1).

Note: Note the position of the different length bolts

and different types of bolts for installation purposes.

14. Use Tooling (A) in order to cap the connection on

fuel fi lter base (1).

23. Remove fuel fi lter base (1) from inlet manifold

(twenty one).

15. Use Tooling (A) in order to cap fuel transfer pump

(14).

24. Remove gasket seal (20).

16. Remove seal (13) (not shown) from tube

assembly (11).

i04638591

Fuel Filter Base-Disassemble

(1606A and 1606D Engines)

17. Use Tooling (A) in order to cap tube assembly

(11).

18. Disconnect tube assembly (16) from fuel fi lter

base (1) and fuel lift pump (14).

Disassembly Procedure

19. Remove seal (15) (not shown) and seal (17) (not

shown) tube assembly (16).

Start By:

20. Use Tooling (A) in order to cap tube assembly

(16).

a. Remove the fuel fi lter base. Refer to Disassembly

and Assembly, “Fuel Filter Base-Remove”.

21. Use Tooling (A) in order to cap the connection on

fuel fi lter base (1) and fuel lift pump (14).

This document is printed from SPI². Not for RESALE


KENR8773

7

Disassembly and Assembly Section

5. Remove Torx screws (10). Remove drain valve (9)

assembly from fuel fi lter base (4).

NOTICE

Ensure that all adjustments and repairs that are

carried out to the fuel system are performed by

authorized personnel that have the correct train-

ing.

6. Remove O-ring (8) (not shown).

Before beginning ANY work on the fuel system, re-

fer to Operation and Maintenance Manual, “Gen-

eral Hazard Information and High Pressure Fuel

Lines ”for safety information.

Refer to System Operation, Testing and Adjusting,

"Cleanliness of Fuel System Components" for de-

tailed information on the standards of cleanliness

that must be observed during ALL work on the fu-

el system.

g02797583

Illustration 5

7. Use a deep socket in order to remove fuel pressure

sensor (14) from fuel fi lter base assembly (4).

8. Remove O-ring seal (16) from the fuel pressure

sensor.

9. Use a suitable tool in order to remove water in fuel

sensor (15) from fuel fi lter base assembly (4).

10. Remove O-ring seal (16) from the water in fuel

sensor.

11. Remove dust cap (13) from fuel sampling valve

(12).

12. Use a deep socket in order to remove fuel

sampling valve (12) from fuel fi lter base assembly

(4).

g02797498

Illustration 4

13. Remove O-ring seal (5) from the fuel sampling

valve.

1. Remove primary fuel fi lter (1). Refer to the

Operation and Maintenance Manual, "Fuel System

Primary Filter-Clean / Inspect / Replace ”for the

correct procedure.

Personal injury can result from being struck by

parts propelled by a released spring force.

2. Remove secondary fuel fi lter (2). Refer to the

Operation and Maintenance Manual, "Fuel

System Secondary Filter-Replace ”for the correct

procedure.

Make sure to wear all necessary protective equip-

ment.

3. Remove connection (3) from fuel fi lter base (4).

Remove O-ring (4) from the connection.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

4. Remove connection (7) from fuel fi lter base (4).

Remove O-ring (6) from the connection.

This document is printed from SPI². Not for RESALE


8

Disassembly and Assembly Section

KENR8773

1. Ensure that the fuel fi lter base is clean, free from

restriction, and free from damage. If necessary,

replace the complete fuel fi lter base and fi lter

assembly.

g03159778

Illustration 6

14. Remove Torx screws (23). Support cover plate

(22) as the Torx screws are loosened.

g03159778

Illustration 7

15. Remove cover plate (22), spring (19), and valve

(18) from fuel fi lter housing (4).

2. Install a new gasket seal (20) to cover plate (22).

Ensure that the gasket seal is correctly seated

into the recess in the cover plate.

16. Ensure that spring locator (21) is not damaged.

17. Remove gasket seal (20).

3. Install valve (18) into fuel fi lter base (4). Ensure

that the valve is correctly installed into the fuel fi lter

housing. Ensure that the valve can freely move.

i04638611

Fuel Filter Base-Assemble

(1606A and 1606D Engines)

4. Install spring (19) into valve (18). Ensure that the

spring is correctly installed into the valve.

5. Position cover plate (22) onto spring (19). Ensure

that spring (19) is correctly located onto locator

(21) in the cover plate.

Assembly Procedure

6. Install Torx screws (23) to cover plate (22).

NOTICE

7. Tighten Torx screws (23) evenly in order to pull

cover plate (22) into position on fuel fi lter base (4).

Ensure that all adjustments and repairs that are

carried out to the fuel system are performed by

authorized personnel that have the correct train-

ing.

8. Tighten Torx screws (23) to a torque of 10 N · m

(89 lb in).

Before beginning ANY work on the fuel system, re-

fer to Operation and Maintenance Manual, “Gen-

eral Hazard Information and High Pressure Fuel

Lines ”for safety information.

Refer to System Operation, Testing and Adjusting,

"Cleanliness of Fuel System Components" for de-

tailed information on the standards of cleanliness

that must be observed during ALL work on the fu-

el system.

This document is printed from SPI². Not for RESALE


KENR8773

9

Disassembly and Assembly Section

g02797583

Illustration 8

9. Install a new O-ring seal (16) from fuel pressure

sensor (17).

10. Install fuel pressure sensor (17) to fuel fi lter base

assembly (4).

g02797498

Illustration 9

11. Use a deep socket in order to tighten fuel pressure

sensor to a torque of 11 Nm (97 lb in).

17. Install a new O-ring (4) to connection (3).

18. Install connection (3) to fuel fi lter base (4). Tighten

the connection to a torque of 18 Nm (159 lb in).

12. Install a new O-ring seal (16) to the water in fuel

sensor.

19. Install a new O-ring (6) to connection (7).

13. Use a suitable tool in order to install water in fuel

sensor (15) to fuel fi lter base assembly (4). Tighten

the fuel sensor to a torque of 2 Nm (18 lb in).

20. Install connection (7) to fuel fi lter base (4). Tighten

the connection to a torque of 18 Nm (159 lb in).

14. Install a new O-ring seal (5) to fuel sampling valve

(12).

21. Install a new O-ring (8) (not shown) into recess

in fuel fi lter base (4). Position drain valve (9)

assembly to fuel fi lter base (4).

15. Use a deep socket in order to install fuel sampling

valve (12) to fuel fi lter base assembly (4). Tighten

the fuel sampling valve to a torque of 17 N · m

(150 lb in).

22. Install Torx screws (10) finger tight.

23. Tighten Torx screws (10) to a torque of 5 N · m

(44 lb in).

16. Install dust cap (13) to fuel sampling valve (12).

24. Ensure that drain valve (9) move freely after the

Torx screws have been tightened.

25. Install a new primary fuel fi lter (1). Refer to the

Operation and Maintenance Manual, "Fuel System

Primary Filter-Clean / Inspect / Replace ”for the

correct procedure.

26. Install a new secondary fuel fi lter (2). Refer to

the Operation and Maintenance Manual, "Fuel

System Secondary Filter-Replace ”for the correct

procedure.

This document is printed from SPI². Not for RESALE


10

KENR8773

Disassembly and Assembly Section

End By:

a. Install the fuel fi lter base. Refer to Disassembly

and Assembly, “Fuel Filter Base-Install”.

i04640250

Fuel Filter Base-Install

(1606A and 1606D engines)

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g03158357

Illustration 10

NOTICE

2. Position a new gasket seal (20) into the recess of

fuel fi lter base (1).

Ensure that all adjustments and repairs that are

carried out to the fuel system are performed by

authorized personnel that have the correct train-

ing.

3. Position fuel fi lter base (1) onto inlet manifold (21).

4. Install bolt (18) and stud bolts (19) to fuel fi lter

base (1). Support the fuel fi lter base as the bolts

are installed.

Before beginning ANY work on the fuel system, re-

fer to Operation and Maintenance Manual, “Gen-

eral Hazard Information and High Pressure Fuel

Lines ”for safety information.

Note: Ensure that the different length bolts and

the different types of bolts are installed to the bolts

original position.

Refer to System Operation, Testing and Adjusting,

"Cleanliness of Fuel System Components" for de-

tailed information on the standards of cleanliness

that must be observed during ALL work on the fu-

el system.

5. Tighten bolt (18) and stud bolts (19) to a torque of

31 Nm (274 lb in).

1. Ensure that the fuel fi lter base is clean and free

from damage. If necessary, replace the complete

fuel fi lter base and fi lter assembly.

g03158102

Illustration 11

This document is printed from SPI². Not for RESALE


KENR8773

11

Disassembly and Assembly Section

6. Remove the caps from the connections on fuel

fi lter base (1) and fuel lift pump (14).

20. Remove the caps from fuel hose assembly and

the return connection (10) on fuel fi lter base (1).

7. Position a new O-ring seal (12) (not shown) onto

the connection on fuel fi lter base (1).

21. Connect the fuel hose assembly onto return

connection (10) on fuel fi lter base (1).

8. Remove the caps from tube assembly (11).

22. Position harness assembly (5) onto the stud bolt

on fuel fi lter base (1). Install nut (4) and tighten the

nut to a torque of 18 N · m (159 lb in). Ensure that

harness assembly (5) is not strained or twisted

as the nut are tightened.

9. Install a new seal (13) (not shown) to tube

assembly (11).

10. Connect tube assembly (11) to fuel fi lter base (1)

and fuel lift pump (14).

23. Connect harness assembly (6) onto the water in

fuel sensor (7) (not shown).

11. Tighten tube nut for tube assembly (11) on fuel

fi lter base (1) to a torque of 31 N · m (22 lb ft).

24. Connect harness assembly (8) onto fuel pressure

sensor (9).

12. Tighten tube nut on tube assembly (11) to a

torque of 18 Nm (159 lb in).

25. If necessary, install hose assembly to inlet

connection (2). Securely tighten hose clamps.

13. Remove the caps from the connections on fuel

fi lter base (1) and fuel lift pump (14).

26. Turn the battery disconnect switch to the ON

position.

14. Remove the caps from tube assembly (16).

27. Turn the fuel supply to the ON position.

15. Install new seal (15) (not shown) and new seal

(17) (not shown) to tube assembly (16).

End By:

16. Connect tube assembly (16) to fuel fi lter base (1)

and fuel lift pump (14).

a. Remove the air from the fuel system. Refer to

the Operation and Maintenance Manual, "Fuel

System-Prime ”for the correct procedure.

17. Tighten tube nuts on tube assembly (16) to a

torque of 18 Nm (159 lb in).

g02797418

Illustration 12

18. Remove the caps from the fuel hose assembly

and inlet connection (3) on fuel fi lter base (1).

19. Connect the fuel hose assembly onto inlet

connection (3) on fuel fi lter base (1).

This document is printed from SPI². Not for RESALE


12

KENR8773

Disassembly and Assembly Section

i04893431

4. Connect harness assembly (6) to switch (5).

Switch (Water in Fuel)-

Remove and Install

(1606A and 1606D Engines)

End By:

a. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System-Prime” for

the correct procedure.

Removal Procedure

i04640253

Fuel Transfer Pump-Remove

(1606A and 1606D Engines)

Removal Procedure

Table 2

Required Tools

Tool

Part Number

Part Description

Capping Kit

Qty

A

29990075

1

NOTICE

Care must be taken to ensure that fl uids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fl uid with suitable containers before open-

ing any compartment or disassembling any compo-

nent containing fl uids.

g03151157

Illustration 13

Dispose of all fl uids according to local regulations and

mandates.

1. Ensure that fuel fi lter base (2) is clean and free

from dirt.

2. Attach a suitable tube onto drain (3). Loosen

cap (1) on fuel fi lter base (2) in order to allow

atmospheric pressure to act upon the fuel. Rotate

the cap three and a half turns in order to allow the

vent hole to be accessed.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

3. Open drain valve (4) and drain fuel from fuel fi lter

base (2). Close drain valve (4).

NOTICE

Ensure that all adjustments and repairs that are

carried out to the fuel system are performed by

authorized personnel that have the correct train-

ing.

4. Tighten cap (1) to a torque of 25 N · m (221 lb in)

5. Disconnect harness assembly (6) from switch (5).

6. Use a suitable tool in order to remove switch (5)

from fuel fi lter base (2).

Before beginning ANY work on the fuel system, re-

fer to Operation and Maintenance Manual, “Gen-

eral Hazard Information and High Pressure Fuel

Lines ”for safety information.

7. Remove O ring seal (7) from switch (5).

Installation Procedure

Refer to System Operation, Testing and Adjusting,

"Cleanliness of Fuel System Components" for de-

tailed information on the standards of cleanliness

that must be observed during ALL work on the fu-

el system.

1. Install a new O ring seal (7) onto switch (5).

2. Use a suitable tool in order to install switch (5) into

fuel fi lter base (2).

1. Turn the battery disconnect switch to the OFF

3. Tighten switch (5) to a torque of 2 Nm (17 lb in).

position.

This document is printed from SPI². Not for RESALE


KENR8773

13

Disassembly and Assembly Section

2. Turn the fuel supply to the OFF position.

g03176033

Illustration 15

g03175857

Illustration 14

10. Attach a suitable tube onto drain (19). Loosen

the cap on the fuel fi lter base in order to allow

atmospheric pressure to act upon the fuel. Rotate

the cap three and a half turns in order to allow the

vent hole to be accessed.

3. Place a suitable container below fuel transfer

pump (6) in order to catch any fuel that might be

spilled.

4. Slide the locking tab into the unlocked position.

Disconnect harness assembly (2).

11. Open drain valve (18) and drain the fuel from the

fuel fi lter base. Close drain valve (18).

5. Slide the locking tab into the unlocked position.

Disconnect harness assembly (3).

12. Tighten the cap on the fuel fi lter base to a torque

of 25 N · m (221 lb in)

6. Remove nut (1) and nut (4) from harness

assembly (7).

13. Loosen tube nut (10) and tube nut (15) on tube

assembly (9) and drain the fuel from the system.

7. Disconnect harness assembly (8) from the water

in fuel sensor.

14. Loosen tube nut (12) and tube nut (16) on tube

assembly (20) and drain the fuel from the system.

8. Slide the locking tab into the unlocked position.

Disconnect harness assembly (5) from the engine

oil temperature sensor.

15. Remove tube assembly (9) and tube assembly

(20).

16. Remove O-ring seal (11) (not shown) from the

connection in the fuel fi lter base. Use Tooling (A) in

order to cap the connection in the fuel fi lter base.

9. Position harness assembly (7) away from transfer

pump (6).

17. Use Tooling (A) in order to cap the connections in

fuel transfer pump (6).

18. Remove seal (14) (not shown) from tube

assembly (9). Use Tooling (A) in order to cap tube

assembly (9)

19. Remove seal (13) (not shown) and seal (17) (not

shown) from tube assembly (20).

20. Use Tooling (A) in order to cap tube assembly (20)

This document is printed from SPI². Not for RESALE


14

KENR8773

Disassembly and Assembly Section

g03176216

g03176276

Illustration 16

Illustration 17

21. If necessary, follow Step 21.a through Step 21.f

in order to remove connections from fuel transfer

pump (6).

25. Remove O ring seal (27) from high-pressure oil

pump (25).

a. Remove connection (21) from fuel transfer

i04640255

pump (6).

Fuel Transfer Pump-Install

(1606A and 1606D Engines)

b. Remove O-ring seal (22) from connection (18).

c. Use Tooling (A) in order to cap connection (21).

d. Remove connection (24) from fuel transfer

pump (6).

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

e. Remove O-ring seal (23) from connection (24).

f. Use Tooling (A) in order to cap connection (24).

Contaminants may cause rapid wear and shortened

component life.

22. Loosen evenly bolts (26) and remove bolts (26)

from transfer pump (6).

1. Ensure that the fuel transfer pump is clean and

free from damage.

23. Remove transfer pump (6) from high-pressure oil

pump (25)

24. Use Tooling (A) in order to plug high-pressure oil

pump (25).

This document is printed from SPI². Not for RESALE


KENR8773

15

Disassembly and Assembly Section

7. Install the connection to transfer pump (6). Tighten

connection (21) to a torque of 18 Nm (159 lb in).

8. Install a new O ring seal (23) to connection (24).

9. Install the connection to transfer pump (6). Tighten

connection (24) to a torque of 18 Nm (159 lb in).

g03176276

Illustration 18

2. Remove the plug from high-pressure oil pump

(25).

3. Position a new O-ring seal (27) into the recess of

high-pressure oil pump (25).

g03176033

Illustration 20

Note: Ensure that the O-ring seal is correctly seated

into the recess of the high-pressure oil pump.

10. Ensure that tube assembly (9) and tube assembly

(20) are clean, free damage, and free from

restriction.

11. Remove the cap from connection on the fuel fi lter

base. Install a new O-ring seal (11) (not shown)

to the connection.

12. Remove the caps from tube assembly (9). Ins, tall

a new seal (14) (not shown) to the tube assembly.

13. Install tube assembly (9) to transfer pump (6).

Tighten tube nut (10) and tube nut (15) for tube

assembly (9) hand tight.

14. Remove caps from tube assembly (20). Install

new seal (14) (not shown) and new seal (14) (not

shown) to the tube assembly.

15. Install tube assembly (20) to transfer pump (6).

Tighten tube nut (12) and tube nut (16) for tube

assembly (20) hand tight.

g03176216

Illustration 19

16. Tighten tube nut (10) to a torque of 31 N · m

(22 lb ft).

4. Position transfer pump (6) onto high-pressure oil

pump (25). Install bolts (26) and tighten the bolts

down evenly.

17. Tighten tube nut (15) to a torque of 18 N · m

(159 lb in).

5. Tighten bolts (26) to a torque of 13 N · m (115 lb in).

6. Install a new O ring seal (22) to connection (21).

18. Tighten tube nut (12) and tube nut (16) to a torque

of 18 Nm (159 lb in).

This document is printed from SPI². Not for RESALE


16

KENR8773

Disassembly and Assembly Section

i04893417

Exhaust Gas Recirculation

Cooler-Remove and Install

(1606D Engines)

Removal Procedure

1. Drain the coolant from the cooling system into

a suitable container for storage or disposal.

Refer to Operation and Maintenance Manual,

"Cooling System Coolant-Change" for the correct

procedure.

g03175857

Illustration 21

19. Position harness assembly (7) onto the stud bolts.

20. Install nut (1) and nut (4) hand tight.

21. Connect harness assembly (5) to the engine oil

temperature sensor. Slide the locking tab into the

locked position.

22. Connect harness assembly (8) to the water in fuel

sensor.

23. Tighten nut (1) to a torque of 18 N · m (159 lb in).

Ensure that harness assembly (7) is not strained

or twisted as the nut are tightened.

g03075897

Illustration 22

24. Tighten nut (4) to a torque of 18 N · m (159 lb in).

Ensure that harness assembly (7) is not strained

or twisted as the nut are tightened.

25. Connect harness assembly (2) and harness

assembly (3). Slide the locking tabs into the locked

position.

26. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System-Prime”.

g03075903

Illustration 23

This document is printed from SPI². Not for RESALE


KENR8773

17

Disassembly and Assembly Section

2. Loosen hose clamp (2) and disconnect hose

assembly (1) from exhaust gas recirculation cooler

(3).

Note: The exhaust gas recirculation cooler

should not be disassembled or cleaned.

2. Ensure that the exhaust gas recirculation cooler is

free from wear and damage. If necessary, replace

exhaust gas recirculation cooler as an assembly.

3. Loosen the hose clamp for hose assembly (9).

4. Remove hose assembly (9) from exhaust gas

recirculation cooler (3).

3. Ensure that all tube assemblies are clean and

free from restriction, wear, and damage. If

necessary, replace any components that are worn

or damaged.

5. Remove bolt (6) and bolt (20) from tube assembly

(7).

6. Loosen hose clamp (22) for tube assembly (7).

7. Remove tube assembly (7) from valve mechanism

cover (5) and hose assembly (21). Remove O-ring

seal (8) (not shown) from tube assembly (7).

8. Prior to and during removal of bolts (11) apply

releasing fl uid to the bolts.

9. Remove bolts (11) and remove gasket (10) (not

shown).

10. Prior to and during removal of bolts (13) apply

releasing fl uid to the bolts.

11. Remove bolts (13).

12. Remove the nut from the assembly of clamp

(4). Position clamp (4) away from exhaust gas

recirculation cooler (3).

g03075897

Illustration 24

13. Remove the clamp plate from exhaust gas

recirculation cooler (3).

14. Remove bolt (17) from tube assembly (16).

15. Remove exhaust gas recirculation cooler (3) from

exhaust manifold (14) and tube assembly (16).

16. Remove gasket (12) (not shown) from exhaust

manifold (14).

17. Remove tube assembly (16) from front housing

(19).

18. Remove O-ring seal (15) (not shown) from O-ring

seal (18) (not shown) from tube assembly (16).

Installation Procedure

Table 3

Required Tools

g03075903

Illustration 25

Tool

Part Number

Part Description

Qty

A

CV60889

Anti-Seize Compound

1

4. Install a new O-ring seal (15) (not shown) and a

new O-ring seal (18) (not shown) to tube assembly

(16).

1. Ensure that the exhaust gas recirculation cooler is

clean and free from restriction. Refer to Systems

Operation, Testing and Adjusting, "Exhaust Cooler

(NRS)-Test ”for the correct procedure.

This document is printed from SPI². Not for RESALE


18

KENR8773

Disassembly and Assembly Section

5. Install tube assembly (16) to front housing

(19). Ensure that the tube assembly is correctly

orientated and is fully installed to the front housing

22. Install a new O-ring seal (8) (not shown) to tube

assembly (7).

23. Install tube assembly (7) to valve mechanism

cover (5) and hose assembly (19). Ensure that

the tube assembly is correctly seated in to valve

mechanism cover (5) and hose assembly (19).

6. Position a new gasket (12) (not shown) onto

exhaust gas recirculation cooler (3). Ensure that

the gasket is correctly seated onto the exhaust

gas recirculation cooler.

24. Install bolt (6) and bolt (18) to tube assembly (7)

hand tight.

7. Position exhaust gas recirculation cooler (3) onto

exhaust manifold (14) and install tube assembly

(16) into exhaust gas recirculation cooler (3).

25. Tighten bolt (6) to a torque of 13 N · m (115 lb in).

26. Tighten bolt (18) to a torque of 62 N · m (45 lb ft).

Note: Ensure that the exhaust gas recirculation

cooler is correctly positioned onto the exhaust

manifold. Ensure that the tube assembly is correctly

seated into the exhaust gas recirculation cooler.

27. Securely tighten hose clamp (20) .for tube

assembly (7).

8. Apply Tooling (A) to the threads of new bolts (13).

Install bolts (13) hand tight.

28. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, "Cooling

System Coolant-Change ”for the correct

procedure.

9. Position a new gasket (10) (not shown) between

exhaust gas recirculation cooler (3) and the tube

assembly.

i04640256

Electronic Unit Injector-

Remove

10. Apply Tooling (A) to the threads of new bolts (11).

Install bolts (11) hand tight.

11. Apply Tooling (A) to the threads of new bolts (17).

Ensure that the clamp for tube assembly (16) is

correctly located into exhaust gas recirculation

cooler (3)

(1606A and 1606D Engines)

Removal Procedure

12. Install bolts (17) hand tight.

13. Position the assembly of clamp (4) onto exhaust

Table 4

gas recirculation cooler (3).

Required Tools

Tool

A

Part Number

27610307

29990075

Part Description

T40 Torx Socket

Capping Kit

Qty

1

Note: Ensure that the clamp is correctly located onto

the exhaust gas recirculation cooler.

B

1

14. Apply Tooling (A) to the threads of the nut for

clamp (4). Install the nut for clamp (4) hand tight.

Start By:

15. Tighten bolts (13) to a torque of 31 N · m (274 lb in).

16. Tighten bolts (11) to a torque of 24 N · m (212 lb in).

17. Tighten bolt (17) to a torque of 31 N · m (274 lb in).

a. Remove the unit injector actuation oil manifold.

Refer to Disassembly and Assembly, "Unit Injector

Actuation Oil Manifold-Remove and Install ".

NOTICE

Keep all parts clean from contaminants.

18. Tighten the nut for clamp (4) to a torque of 8 N · m

(71 lb in).

Contaminants may cause rapid wear and shortened

component life.

19. Connect hose assembly (1) to exhaust gas

recirculation cooler (3). Tighten hose clamp (2)

securely.

1. Turn the fuel supply to the OFF position.

20. Install hose assembly (9) to exhaust gas

recirculation cooler (3).

21. Tighten the hose clamp for hose assembly (9)

securely.

This document is printed from SPI². Not for RESALE


KENR8773

19

Disassembly and Assembly Section

6. Remove O-ring seal (4) and O-ring seal (5) from

electronic unit injector (1).

7. Use a suitable tool in order to remove sealing

washer (6) from electronic unit injector (1). Ensure

that the sealing washer is removed from the

cylinder head.

Note: Ensure that the nozzle for the electronic unit

injector is not damaged in any way on removal of the

sealing washer.

8. Use Tooling (C) in order to cap and plug electronic

unit injector (1).

9. If necessary, follow Step 1 through Step 8 in order

to remove the remaining electronic unit injectors.

i04640270

Electronic Unit Injector-Install

(1606A and 1606D Engines)

g03174696

Illustration 26

2. Place an identi fi cation mark on electronic unit

injector (1) for installation purposes. Each

electronic unit injector must be reinstalled in the

original location in the cylinder head.

Installation Procedure

3. Use Tooling (A) to loosen fully Torx bolt (2). As

Torx bolt (2) is loosened, the electronic unit injector

will self extract from the cylinder head.

Table 5

Required Tools

Tool

D

Part Number

GE50028

Part Description

Vacuum Pump

Qty

1

4. Remove electronic unit injector (1) and clamp

assembly (3) from the cylinder head.

GE50046

Fluid Sampling Bottle

1

Note: Always handle electronic unit injector with care.

Tube

7.9 mm (0.31 inch) OD

GE50030

-

1

1

E

Large Bore Brush

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Use Tooling (E) to clean the carbon deposit from

the inside of the electronic unit injector sleeve.

2. Use Tooling (D) to remove the fuel and oil from

the cylinder. Evacuate as much fuel and oil as

possible from the cylinder before installing the

electronic unit injector. Several evacuations may

be necessary.

g03174716

Illustration 27

5. Remove clamp assembly (3) from electronic unit

injector (1).

This document is printed from SPI². Not for RESALE


20

KENR8773

Disassembly and Assembly Section

g03174796

g03174696

Illustration 28

Illustration 30

3. Ensure that the seat Area (X) of electronic unit

injector (1) is clean and free from carbon.

6. Position clamp assembly (3) on to electronic unit

injector (1). Ensure that the clamp assembly is

correctly located into the electronic unit injector

in Position (Y).

4. Install a new O-ring seal (4) and a new O-ring seal

(5) onto the electronic unit injector.

7. Install electronic unit injector (2) into the original

5. Install a new sealing washer (6) onto electronic

location in the cylinder head.

unit injector (1).

8. Use Tooling (A) in order to tighten Torx bolt (2)

Note: Ensure that the nozzle for the electronic unit

injector is not damaged in any way as a new sealing

washer is installed.

hand tight.

9. Tighten Torx bolt (4) to a torque of 41 N · m (30 lb ft).

10. If necessary, repear Step 1 through Step 9 in

order to install the remaining electronic unit

injectors (2).

11. Turn the fuel supply to the ON position.

12. Install the unit injector actuation oil manifold.

Refer to Disassembly and Assembly, "Unit Injector

Actuation Oil Manifold-Remove and Install ".

13. Remove the air from the fuel system. Refer to

Systems Operation, Testing and Adjusting, "Fuel

System-Prime ".

g03174836

Illustration 29

This document is printed from SPI². Not for RESALE


KENR8773

twenty one

Disassembly and Assembly Section

i04640271

Electronic Unit Injector Sleeve

-Remove

(1606A and 1606D Engines)

Removal Procedure

Table 6

Required Tools

Tool

Part Number

Part Description

Qty

(1 "x 8 TPI UNC) Thread

Tap

1

A

27610362

Guide

1

1

1

Adapter

B

C

27610311

-

Slide Hammer Puller

(5/8 "X 18 TPI UNF) by 4"

Long Stud

1

Start By:

a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, "Electronic Unit

Injector-Remove ".

g03175098

Illustration 31

2. Plugging of an electronic unit injector sleeve (1)

will be necessary in order to stop debris entering

the cylinder bore. Plugging of the electronic unit

injector sleeve will only be required if the cylinder

head in still installed to the engine

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

3. Apply lubricant to the thread tap of Tooling (A).

Use the guide and the threaded tap of Tooling (A)

in order to cut a thread in electronic unit injector

sleeve (1). Screw in the thread tap of Tooling (A)

into the electronic unit injector sleeve by 19 mm

(0.75 inch).

1. Drain the coolant from the engine. Refer to

Operation and Maintenance Manual, "Cooling

System Coolant-Change ".

4. Remove both the guide and the thread tap of

Tooling (A) from the electronic unit injector sleeve.

This document is printed from SPI². Not for RESALE


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