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Products
Perkins 2206-E13 engine disassembly and assembly manual


Detailed Description:

Disassembly and

Assembly

2206-E13 Industrial Engine

Table of Contents

Front Plate-Install ............... .. 57

Crankcase Breather-Remove and Install (Closed

Breather) ... ............. 58

Crankcase Breather-Remove and Install (Open

Breather) ... ............. 59

Valve Mechanism Cover-Remove and Install ..... 60

Valve Mechanism Cover Base-Remove and

Disassembly and Assembly Section

Fuel Priming Pump-Remove and Install .............. 5

Fuel Filter Base-Remove ..................................... 6

Fuel Filter Base-Disassemble ............... 6

Fuel Filter Base-Assemble ...

Fuel Filter Base-Install ......... 7

Fuel Transfer Pump-Remove ............ 8

Fuel Transfer Pump-Install ......... 9

Electronic Unit Injector-Remove ........................... 9

Electronic Unit Injector-Install ............. 10

Electronic Unit Injector Sleeve-Remove .............. 11

Electronic Unit Injector Sleeve-Install ... 12

Air Cleaner-Remove and Install ............... 13

Turbocharger-Remove .............. 13

Turbocharger-Install ............ 14

Exhaust Manifold-Remove and Install ............... 16

Exhaust Elbow-Remove and Install ... 17

Inlet Manifold-Remove and Install ........... 17

Inlet and Exhaust Valve Springs-Remove and

Install ....................................... ........ 61

Rocker Shaft and Pushrod-Remove ... 64

Rocker Shaft-Disassemble ...

Rocker Shaft-Assemble ...

Rocker Shaft and Pushrod-Install ......... 66

Cylinder Head-Remove ...

Cylinder Head-Install ...

Lifter Group-Remove ..................................... 72

Lifter Group-Disassemble ...

Lifter Group-Assemble ...

Lifter Group-Install ............... 74

Camshaft-Remove .............................. 75

Camshaft-Install ............... ... 76

Camshaft Gear-Remove and Install .. 78

Camshaft Bearings-Remove ............... 79

Camshaft Bearings-Install ...

Engine Oil Pan-Remove and Install ......... 80

Cylinder Liner-Remove ........................ 83

Cylinder Liner-Install ........................... 83

Piston Cooling Jets-Remove and Install ............. 84

Pistons and Connecting Rods-Remove .............. 85

Pistons and Connecting Rods-Disassemble ....... 86

Pistons and Connecting Rods-Assemble ........... 87

Pistons and Connecting Rods-Install ........ 88

Crankshaft Main Bearings-Remove (Crankshaft in

position) ................................... .............. 89

Crankshaft Main Bearings-Install (Crankshaft in

position) ................................... .............. 90

Crankshaft-Remove ............................ 92

Crankshaft-Install ............... . 94

Crankshaft Gear-Remove and Install ...... 96

Bearing Clearance-Check ...

Atmospheric Pressure Sensor-Remove and

Install ....................................... .................. 19

Inlet and Exhaust Valves-Remove and Install .... 21

Inlet and Exhaust Valve Guides-Remove and

Install ....................................... .................. twenty three

Engine Oil Filter Base-Remove ........... 24

Engine Oil Filter Base-Disassemble ......... 25

Engine Oil Filter Base-Assemble .............. 27

Engine Oil Filter Base-Install .............. 28

Engine Oil Cooler-Remove ........................ 29

Engine Oil Cooler-Install ........................... 30

Engine Oil Pump-Remove ..................... 32

Engine Oil Pump-Disassemble ........... 33

Engine Oil Pump-Assemble ...

Engine Oil Pump-Install ............ 34

Water Pump-Remove ......... 35

Water Pump-Install .............. 37

Water Temperature Regulator Housing-Remove and

Install ....................................... .. 38

Engine Support (Front)-Remove and Install ....... 40

Flywheel-Remove ............................... 41

Flywheel-Install ............... .... 41

Crankshaft Rear Seal-Remove ................. 43

Crankshaft Rear Seal-Install ............... 43

Crankshaft Wear Sleeve (Rear)-Remove and

Install ....................................... ........ 44

Flywheel Housing-Remove and Install .............. 45

Vibration Damper and Pulley-Remove and Install

........................................ ................. 47

Crankshaft Front Seal-Remove ........... 48

Crankshaft Front Seal-Install .............. 49

Crankshaft Wear Sleeve (Front)-Remove and

Install ....................................... ........ 50

Front Cover-Remove .......................... 51

Front Cover-Install .............................. 51

Gear Group (Front)-Remove .............. 52

Gear Group (Front)-Install ...

Housing (Front)-Remove ...

Housing (Front)-Install ...

Front Plate-Remove ............................ 56

Install ....................................... .................. 98

Camshaft Position Sensor-Remove and Install: 99

Crankshaft Position Sensor-Remove and

Install ....................................... ...... 100

Coolant Temperature Sensor-Remove and

Install ....................................... ...... 101

Engine Oil Pressure Sensor-Remove and Install

........................................ ......................... 102

Fuel Temperature Sensor-Remove and Install: 103

Inlet Manifold Temperature Sensor-Remove and

Install ....................................... ...... 104

Inlet Manifold Pressure Sensor-Remove and

Install ....................................... ...... 105

Belt Tightener-Remove ..................................... 105

Belt Tightener-Install ...

Fan-Remove and Install ...

Fan Drive-Remove ............... 107

Fan Drive-Disassemble ...

Fan Drive-Assemble ...

Fan Drive-Install ............... ... 112

Pump Drive-Remove (Transfer pump) ............... 113

Pump Drive-Disassemble (Transfer pump) ........ 113

Pump Drive-Assemble (Transfer pump) ............ 113

This document has been printed from SPI². Not for Resale


4

KENR6906

Table of Contents

Pump Drive-Install (Transfer pump) ......... 114

Electronic Control Module-Remove and Install: 114

Alternator-Remove and Install ........... 116

Electric Starting Motor-Remove and Install ... 117

Index Section

Index ............................. ................... 118

This document has been printed from SPI². Not for Resale


KENR6906

5

Disassembly and Assembly Section

Disassembly and Assembly

Section

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

i02736695

Fuel Priming Pump-Remove

and Install

Contaminants may cause rapid wear and shortened

component life.

Removal Procedure

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.

Dispose of all fl uids according to local regulations and

mandates.

NOTICE

Keep all parts clean from contaminants.

g01380207

Contaminants may cause rapid wear and shortened

component life.

Illustration 2

Typical example

1. Position a new joint (3) on fuel fi lter base (4).

Note: Ensure correct orientation of the joint.

1. Turn the fuel supply to the “OFF” position.

2. Position fuel priming pump (1) on fuel fi lter base

(4) and install bolts (2). Tighten the 1/4 "bolt to a

torque of 12 N · m (105 lb in). Tighten the 5/16 "bolt

to a torque of 25 Nm (221 lb in).

3. Turn the fuel supply to the “ON” position.

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

Operation and Maintenance Manual, "Fuel System

-Prime ".

g01380207

Illustration 1

Typical example

2. Remove bolts (2). Remove fuel priming pump (1)

from fuel fi lter base (4).

3. Remove joint (3).

This document has been printed from SPI². Not for Resale


6

Disassembly and Assembly Section

KENR6906

i02754755

5. Disconnect hose assembly (2). Disconnect hose

assembly (4). Disconnect hose assemblies (3)

and (5). Cap the hose assemblies.

Fuel Filter Base-Remove

6. Remove fuel fi lters (9) and (10). Remove the

O-ring seals and the fuel fi lter elements from the

fuel fi lters. Refer to Operation and Maintenance

Manual, “Fuel System Primary Filter-Replace”

and refer to Operation and Maintenance Manual,

“Fuel System Secondary Filter-Replace” for more

information.

Removal Procedure

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.

7. Remove bolts (6). Remove fuel fi lter base (8).

i02754756

Fuel Filter Base-Disassemble

Dispose of all fl uids according to local regulations and

mandates.

NOTICE

Keep all parts clean from contaminants.

Disassembly Procedure

Start By:

Contaminants may cause rapid wear and shortened

component life.

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

and Assembly, “Fuel Filter Base-Remove”.

1. Turn the fuel supply to the “OFF” position.

NOTICE

Keep all parts clean from contaminants.

2. Place a suitable container below the fuel fi lter

base in order to drain the fuel.

Contaminants may cause rapid wear and shortened

component life.

g01380210

Illustration 4

Typical example

g01380208

1. Remove fuel priming pump (4) from fuel fi lter

base (1). Refer to Disassembly and Assembly,

"Fuel Priming Pump-Remove and Install" for the

correct procedure.

Illustration 3

Typical example

3. Remove plugs (11) and (12). Allow the fuel to

drain.

2. Remove fuel temperature sensor (2) from fuel fi lter

base (1). Refer to Disassembly and Assembly,

"Fuel Temperature Sensor-Remove and Install"

for the correct procedure.

4. Slide the locking tab into the unlocked position

and disconnect harness assembly (1) from fuel

temperature sensor (7).

This document has been printed from SPI². Not for Resale


KENR6906

7

Disassembly and Assembly Section

3. Remove fuel bypass valve (6) (not shown) from

fuel fi lter base (1). Remove the O-ring seals from

the fuel bypass valve.

Note: Ensure correct orientation of the connections.

4. Install new O-ring seals to fuel bypass valve (6)

(not shown). Install the fuel bypass valve to fuel

fi lter base (1). Tighten the fuel bypass valve to a

torque of 35 Nm (26 lb ft).

4. Remove fuel check valve (10) from fuel fi lter base

(1). Remove the O-ring seals from the fuel check

valve.

5. Install new O-ring seals to fuel check valve (10).

Install the fuel check valve to fuel fi lter base (1).

Tighten the fuel check valve to a torque of 35 N · m

(26 lb ft).

5. Remove connections (3), (5), (7) and (8) from fuel

fi lter base (1). Remove the O-ring seals from the

connections.

6. Remove plugs (9), (11) and (12) from fuel fi lter

base (1). Remove the O-ring seals from the plugs.

6. Install fuel temperature sensor (2) to fuel fi lter

base (1). Refer to Disassembly and Assembly,

"Fuel Temperature Sensor-Remove and Install"

for the correct procedure.

i02754757

Fuel Filter Base-Assemble

7. Install fuel priming pump (4) to fuel fi lter base

(1). Refer to Disassembly and Assembly, "Fuel

Priming Pump-Remove and Install ”for the

correct procedure.

Assembly Procedure

End By:

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

and Assembly, “Fuel Filter Base-Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

i02754758

Fuel Filter Base-Install

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

from damage. If necessary, replace the fuel fi lter

base.

Installation Procedure

Table 1

Required Tools

Part

Tool

Number

Part Description

Qty

POWERPART

Special Lubricant

A

CV60889

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01380210

Illustration 5

Typical example

2. Install new O-ring seals to plugs (9), (11) and (12).

Install the plugs to fuel fi lter base (1). Tighten plug

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

(11) and (12) to a torque of 15 Nm (11 lb ft).

3. Install new O-ring seals to connections (3), (5),

(7) and (8). Install the connections to fuel fi lter

base (1). Tighten connections (3), (5) and (7) to a

torque of 15 N · m (11 lb ft). Tighten connection (8)

to a torque of 41 Nm (30 lb ft).

This document has been printed from SPI². Not for Resale


8

Disassembly and Assembly Section

KENR6906

i02754760

Fuel Transfer Pump-Remove

Removal Procedure

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.

Dispose of all fl uids according to local regulations and

mandates.

NOTICE

g01380208

Keep all parts clean from contaminants.

Illustration 6

Typical example

Contaminants may cause rapid wear and shortened

component life.

1. Position fuel fi lter base (8) onto the mounting

bracket and install bolts (6). Tighten the bolts to a

torque of 55 Nm (41 lb ft).

1. Turn the fuel supply to the “OFF” position.

2. Install new O-ring seals and new fuel fi lter

elements to fuel fi lters (9) and (10). Apply Tooling

(A) to the threads of the fuel fi lters. Install the fuel

fi lters to fuel fi lter base (8). Tighten the fuel fi lters.

2. Place a suitable container below the fuel transfer

pump in order to catch any fuel that might be

spilled.

Refer to Operation and Maintenance Manual,

"Fuel Filter Primary Filter-Replace" and refer to

Operation and Maintenance Manual, "Fuel Filter

Secondary Filter-Replace ”for more information.

3. Install new O-ring seals to plugs (11) and (12).

Install the plugs to fuel fi lters (9) and (10).

4. Connect hose assemblies (2), (3), (4) and (5).

5. Connect harness assembly (1) to fuel temperature

sensor (7). Slide the locking tab into the locked

position.

6. Turn the fuel supply to the “ON” position.

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

Operation and Maintenance Manual, "Fuel System

-Prime ".

g01380887

Illustration 7

Typical example

3. Disconnect hose assemblies (1) and (2) from fuel

transfer pump (4). Cap the hose assemblies.

4. Remove bolts (3) and remove fuel transfer pump

(4).

This document has been printed from SPI². Not for Resale


KENR6906

9

Disassembly and Assembly Section

5. Remove the O-ring seal from fuel transfer pump

(4).

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

Systems Operation and Maintenance Manual,

"Fuel System-Prime".

i02754761

Fuel Transfer Pump-Install

i02754762

Electronic Unit Injector-

Remove

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Removal Procedure

Table 2

Contaminants may cause rapid wear and shortened

component life.

Required Tools

Tool

Part Number

Part Description

Qty

1. Ensure that the fuel transfer pump is clean and

A

27610288

Pry Bar

1

free from damage.

Start By:

a. Remove the rocker shafts. Refer to Disassembly

and Assembly, "Rocker Shaft and Pushrod-

Remove ".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Turn the fuel supply to the OFF position.

g01416997

Illustration 8

Typical example

2. Lubricate a new O-ring seal with clean engine oil.

Install the O-ring seal to fuel transfer pump (4).

3. Position fuel transfer pump (4) on pump drive (5).

g01411598

Illustration 9

Note: Ensure that the splines on the shaft of the fuel

transfer pump are correctly engaged into the pump

drive.

2. Disconnect hoses (1) and (2) from the fuel fi lter

base in order to drain fuel from the cylinder head.

4. Install bolts (3). Tighten the bolts to a torque of

55 Nm (41 lb ft).

5. Remove the caps from the hose assemblies.

Connect hose assemblies (1) and (2) to fuel

transfer pump (4).

6. Turn the fuel supply to the “ON” position.

This document has been printed from SPI². Not for Resale


10

KENR6906

Disassembly and Assembly Section

i02754763

Electronic Unit Injector-Install

Installation Procedure

Table 3

Required Tools

Tool

B

Part Number

GE50023

GE50024

GE50028

GE50046

Part Description

Tapered Brush

Qty

1

C

Small Bore Brush

Vacuum Pump

1

g01380214

Illustration 10

1

3. Disconnect harness assembly (3) from electronic

Fluid Sampling Bottle

1

unit injector (4).

D

E

Tube

7.9 mm (0.31 inch)

OD

GE50030

1

1

4. Remove bolt (5).

5. Place an identi fi cation mark on electronic unit

injector (4) for installation purposes. Each

electronic unit injector must be reinstalled in the

original location in the cylinder head.

27610296

Torque Wrench

NOTICE

Keep all parts clean from contaminants.

6. Use Tooling (A) to pry beneath clamp (6) and free

electronic unit injector (4).

Contaminants may cause rapid wear and shortened

component life.

7. Remove electronic unit injector (4) and clamp (6)

from the cylinder head.

1. Use Tooling (B) and (C) 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.

g01380213

Illustration 11

8. Remove O-ring seals (7) and (8) from electronic

unit injector (4).

g01380273

Illustration 12

3. Ensure that seat area (X) on electronic unit injector

(4) is clean and free carbon.

This document has been printed from SPI². Not for Resale


KENR6906

11

Disassembly and Assembly Section

4. Install new O-ring seals (7) and (8) to electronic

unit injector (4). Lubricate the O-ring seals with

clean engine oil.

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

Operation and Maintenance Manual, "Fuel System

-Prime ".

5. Install a new O-ring seal (9) to electronic unit

End By:

injector (4).

a. Install the rocker shafts. Refer to Disassembly and

Note: O-ring seal (9) should be installed dry.

Assembly, “Rocker Shaft and Pushrod-Install”.

NOTICE

i02754765

Electronic Unit Injector Sleeve

-Remove

If a replacement electronic unit injector is installed, the

calibration code must be programmed into the elec-

tronic control module. Refer to Troubleshooting Guide,

“Injector Trim File” for more information.

Removal Procedure

Table 4

Required Tools

Tool

Part Number

Part Description

Qty

A

GE50021

Injector Sleeve Tool

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01380214

Illustration 13

6. Install clamp (6) to electronic unit injector (4).

Install electronic unit injector (4) into the original

location in the cylinder head.

1. Drain the coolant from the cooling system into

a suitable container for storage or for disposal.

Refer to Operation and Maintenance Manual,

"Cooling System Coolant-Change".

7. Install bolt (5). Tighten the bolt to a torque of

55 Nm (41 lb ft).

2. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, "Electronic Unit

Injector-Remove ".

8. Connect harness assembly (3) to electronic unit

injector (4). Use Tooling (E) to tighten the nuts to a

torque of 2.5 Nm (22 lb in).

g01391954

Illustration 15

g01411598

Illustration 14

3. Install Tooling (A) into electronic unit injector

sleeve (1).

9. Connect hoses (1) and (2) to the fuel fi lter base.

10. Turn the fuel supply to the “ON” position.

This document has been printed from SPI². Not for Resale


12

KENR6906

Disassembly and Assembly Section

4. Tighten the nut on Tooling (A) until electronic unit

injector sleeve (1) is pulled free from the cylinder

head.

g01043165

Illustration 17

g01393881

Illustration 16

5. Remove O-ring seals (2) and O-ring seal (3) from

electronic unit injector sleeve (1).

i02754766

Electronic Unit Injector Sleeve

-Install

Installation Procedure

Table 5

Required Tools

Tool

Part Number

GE50021

GE50023

GE50024

GE50022

CV60893

Part Description

Injector Sleeve Tool

Tapered Brush

Qty

1

g01393891

Illustration 18

A

1

2. Install new O-ring seals (2) and (3) to electronic

unit injector sleeve (1).

B

C

Small Bore Brush

End Brush

1

1

3. Install electronic unit injector sleeve (1) to Tooling

(A).

Retaining Compound

1

4. Apply a small continuous bead of Tooling (C) to

NOTICE

surface (X) of electronic unit injector sleeve (1).

Keep all parts clean from contaminants.

5. Lubricate O-ring seals (2) with clean engine oil.

Contaminants may cause rapid wear and shortened

component life.

6. Position electronic unit injector sleeve (1) and

Tooling (A) in the cylinder head. Use care not to

damage O-ring seals (2) and (3).

1. Use Tooling (B) to clean the bore in the cylinder

head for the electronic unit injector sleeve.

7. Use Tooling (A) and a soft faced hammer to install

electronic unit injector sleeve (1) to the cylinder

head.

NOTICE

Ensure that the electronic unit injector sleeve and the

cylinder head bore are completely free of oil, dirt, and

sealant debris.

Note: Ensure that the electronic unit injector sleeve

is properly seated in the cylinder head.

This document has been printed from SPI². Not for Resale


KENR6906

13

Disassembly and Assembly Section

8. Install the electronic unit injectors. Refer to

Disassembly and Assembly, "Electronic Unit

Injector-Install ".

Installation Procedure

9. Fill the cooling system with coolant. Refer to

Operation and Maintenance, "Cooling System

Coolant-Change ".

i02754770

Air Cleaner-Remove and

Install

g01380888

Removal Procedure

Illustration 20

Typical example

NOTICE

Keep all parts clean from contaminants.

1. If necessary, position mounting bracket (4) on the

cylinder head and install the bolts that secure

the mounting bracket. Tighten theM12 bolts to a

torque of 100 N · m (74 lb ft). Tighten the 3/8 "bolts

to a torque of 47 Nm (35 lb ft).

Contaminants may cause rapid wear and shortened

component life.

2. Position air cleaner (3) on mounting bracket (4).

Ensure the correct orientation of the air cleaner.

3. Install fasteners (1). Tighten the fasteners to a

torque of 55 Nm (41 lb ft).

4. Connect hose (2) and tighten the hose clamp

securely.

i02754771

Turbocharger-Remove

g01380888

Illustration 19

Typical example

Removal Procedure

1. Loosen the hose clamp and disconnect hose (2).

Start By:

2. Remove fasteners (1) and remove air cleaner (3)

from mounting bracket (4). Note the orientation

of the air cleaner.

a. Remove the exhaust elbow. Refer to Disassembly

and Assembly, "Exhaust Elbow-Remove and

Install ".

3. If necessary, remove the bolts that secure

mounting bracket (4) and remove the mounting

bracket.

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.

Dispose of all fl uids according to local regulations and

mandates.

This document has been printed from SPI². Not for Resale


14

KENR6906

Disassembly and Assembly Section

c. Remove tube assembly (2) and joint (3) from

turbocharger (4).

NOTICE

Keep all parts clean from contaminants.

3. Follow Steps 3 through 3.c in order to remove the

tube assembly for the oil drain to the turbocharger.

Contaminants may cause rapid wear and shortened

component life.

a. Remove bolts (6) and (7).

b. Remove tube assembly (8).

c. Remove joints (5) and (9).

1. Disconnect the air hoses from the turbocharger

inlet and from the turbocharger outlet.

4. Attach a suitable lifting device to turbocharger (4).

The weight of the turbocharger is approximately

32 kg (71 lb).

g01382805

Illustration 22

Typical example

5. Remove nuts (10). Use the lifting device to remove

turbocharger (4) from the exhaust manifold.

6. Remove gasket (11).

i02754772

Turbocharger-Install

g01380889

Illustration 21

Installation Procedure

Typical example

Table 6

2. Follow Steps 2.a through 2.c in order to remove the

Required Tools

Part

tube assembly for the oil feed to the turbocharger.

a. Disconnect tube assembly (2) from the engine

oil fi lter base.

Tool

Number

Part Description

Qty

A

CV60889

Anti-Seize Compound

1

b. Remove bolts (1).

This document has been printed from SPI². Not for Resale


KENR6906

15

Disassembly and Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Ensure that all mating surfaces are clean and free

from damage.

g01382805

Illustration 23

Typical example

2. Position a new gasket (11) on the exhaust

manifold.

3. Attach a suitable lifting device to turbocharger

(4). The weight of turbocharger is approximately

32 kg (71 lb). Use the lifting device to install the

turbocharger to the exhaust manifold.

g01413397

Illustration 24

4. Apply Tooling (A) to the threads of the exhaust

Typical example

manifold studs.

6. Follow Steps 6.a through 6.c in order to install the

tube assembly for the oil drain to the turbocharger.

5. Install nuts (10). Tighten the nuts to a torque of

55 Nm (41 lb ft).

a. Place a new joint (9) and tube assembly (8) in

position and install bolts (7) finger tight.

If a new turbocharger is installed, loosen the

V-band clamps and rotate the bearing housing and

the compressor housing to the correct positions.

b. Position a new joint (5) between turbocharger

(4) and tube assembly (8). Install bolts (6)

finger tight.

c. Tighten bolts (6) and (7) to a torque of 28 N · m

(21 lb ft).

7. Lubricate the bearings of turbocharger (4) with

clean engine oil through oil inlet port (X). Rotate

the shaft of the turbocharger in order to distribute

the lubricant.

This document has been printed from SPI². Not for Resale


16

KENR6906

Disassembly and Assembly Section

8. Follow Steps 8.a through 8.c in order to install the

Note: Remove the manifolds as one assembly.

tube assembly for the oil feed to the turbocharger.

3. Remove the exhaust manifold gaskets.

a. Place a new joint (3) and tube assembly (2) in

position on turbocharger (4).

4. Remove exhaust manifolds (4) and (6) from

exhaust manifold (5).

b. Install bolts (1). Tighten the bolts to a torque of

28 Nm (21 lb ft).

5. If necessary, remove the taperlock studs from the

cylinder head.

c. Connect tube assembly (2) to the engine oil

fi lter base.

Installation Procedure

9. Connect the air hoses to the turbocharger inlet

and the turbocharger outlet.

Table 7

Required Tools

If a new turbocharger was installed, tighten the

V-band clamp for the exhaust housing to 13.5 Nm

(120 lb in). Tighten the V-band clamp for the

compressor housing to 18 Nm (160 lb in).

Tool

Part Number

Part Description

Qty

A

CV60889

Anti-Seize Compound

1

NOTICE

Keep all parts clean from contaminants.

End By:

a. Install the exhaust elbow. Refer to Disassembly

and Assembly, "Exhaust Elbow-Remove and

Install "

Contaminants may cause rapid wear and shortened

component life.

1. If necessary, install the taperlock studs to the

cylinder head. Tighten the taperlock studs to a

torque of 35 Nm (26 lb ft).

i02754773

Exhaust Manifold-Remove

and Install

Removal Procedure

Start By:

a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger-Remove”.

g01380890

Illustration 26

2. Assemble exhaust manifolds (4), (5) and (6).

3. Position the exhaust manifold gaskets onto the

taperlock studs.

4. Install the assembly of the exhaust manifolds to

the cylinder head.

Note: Ensure that the holes in exhaust manifolds are

centralized with the taperlock studs.

g01380890

Illustration 25

5. Apply Tooling (A) to the threads of the taperlock

studs. Install spacers (1), washers (2) and nuts (3).

1. Remove nuts (3), washers (2) and spacers (1).

2. Remove exhaust manifolds (4), (5) and (6).

This document has been printed from SPI². Not for Resale


KENR6906

17

Disassembly and Assembly Section

Installation Procedures

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01380891

Illustration 27

1. Thoroughly clean the exhaust elbow and the outlet

of the turbocharger. Inspect the components for

wear or damage. Replace any components that

are worn or damaged.

6. Tighten the nuts to a torque of 55 N · m (41 lb ft) in

a numerical sequence that is shown in Illustration

27.

End By:

a. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger-Install”.

i02754774

Exhaust Elbow-Remove and

Install

Removal Procedure

g01382827

Illustration 29

NOTICE

Keep all parts clean from contaminants.

2. Position clamp (1) and install exhaust elbow (3)

to turbocharger (2). Ensure correct orientation of

the clamp.

Contaminants may cause rapid wear and shortened

component life.

3. Tighten clamp (1) to a torque of 14 Nm (10 lb ft).

i02763449

Inlet Manifold-Remove and

Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01382827

Illustration 28

1. Loosen clamp (1).

2. Remove exhaust elbow (3) and clamp (1) from

turbocharger (2).

This document has been printed from SPI². Not for Resale


18

KENR6906

Disassembly and Assembly Section

6. Remove fasteners (8). Note the position of the

brackets that are retained by the fasteners.

7. Remove inlet manifold (7) from the cylinder,, head.

8. Remove gasket (10) (not shown).

9. If necessary, remove inlet manifold pressure

sensor (3) and remove inlet manifold temperature

sensor (6) from inlet manifold (7). Refer to

Disassembly and Assembly, "Inlet Manifold

Pressure Sensor-Remove and Install ”and

Disassembly and Assembly, "Inlet Manifold

Temperature Sensor-Remove and Install ”for

more information.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

g01383308

Illustration 30

Contaminants may cause rapid wear and shortened

component life.

Typical example

1. Loosen the hose clamps and disconnect air hose

(1) from connection (2).

1. Ensure that all mating surfaces are clean and free

from debris.

2. Slide the locking tab into the unlocked position

and disconnect harness assembly (4) from inlet

manifold pressure sensor (3).

3. Slide the locking tab into the unlocked position

and disconnect harness assembly (4) from inlet

manifold temperature sensor (6).

4. Loosen clamp (5) and remove connection (2) from

inlet manifold (7).

Note: Make a temporary mark in order to show the

orientation of the connection.

g01384161

Illustration 32

Typical example

2. Place a new gasket (10) (not shown) in position

on inlet manifold (7).

3. Position inlet manifold (7) on the cylinder head.

4. Install fasteners (8). Ensure that the brackets that

are retained by the fasteners are installed in the

correct positions.

5. Tighten fasteners (8) to a torque of 55 N · m

(41 lb ft).

g01384161

Illustration 31

Typical example

6. Install a new O-ring seal (9) to inlet manifold (7).

5. Remove O-ring seal (9) from inlet manifold (7).

This document has been printed from SPI². Not for Resale


KENR6906

19

Disassembly and Assembly Section

i02754775

Inlet and Exhaust Valve

Springs-Remove and Install

Removal Procedure

Table 8

Required Tools

Tool

A

Part Number

CH11148

Part Description

Engine Turning Tool

Qty

1

B

CVT0003

Valve Spring Compressor

1

Start By:

a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, "Electronic Unit

Injector-Remove ".

g01383308

Illustration 33

Typical example

7. Install connection (2) and clamp (5) to inlet

manifold (7). Tighten the clamp to a torque of

14 Nm (10 lb ft).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Note: Ensure correct orientation of the connection.

8. If necessary, install inlet manifold pressure sensor

(3) and install inlet manifold temperature sensor

(6) to inlet manifold (7). Refer to Disassembly

and Assembly, "Inlet Manifold Pressure Sensor

-Remove and Install ”and Disassembly and

Assembly, "Inlet Manifold Temperature Sensor-

Remove and Install ”for more information.

Note: The following procedure should be adopted in

order to remove the valve springs when the cylinder

head is installed to the engine. Refer to Disassembly

and Assembly, "Inlet and Exhaust Valves-Remove

and Install ”for the procedure to remove the valve

springs from a cylinder head that has been removed

from the engine.

9. Connect harness assembly (4) to inlet manifold

pressure sensor (3) and slide the locking tab into

the locked position.

1. Use Tooling (A) to position the appropriate piston

at the top center position before the valve spring

is removed.

10. Connect harness assembly (4) to inlet manifold

temperature sensor (6) and slide the locking tab

into the locked position.

Note: Failure to ensure that the piston is at the top

center position may allow the valve to drop into the

cylinder bore.

11. Connect air hose (1) to connection (2) and tighten

the hose clamps securely.

NOTICE

Do not turn the crankshaft while the valve springs are

removed.

Note: Valve springs must be replaced in pairs for the

inlet valves or the exhaust valves of each cylinder. 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 6, 2 with 5, and 3 with 4.

Ensure that all of the valve springs are installed

before changing from one pair of cylinders to another

pair of cylinders.

This document has been printed from SPI². Not for Resale


20

KENR6906

Disassembly and Assembly Section

8. Remove spring seats (7) from the valve guides.

g01411612

Illustration 35

9. If necessary, remove valve stem seals (8).

Installation Procedure

g01380893

Illustration 34

Table 9

Required Tools

Tool

Part Number

Part Description

Qty

Personal injury can result from being struck by

parts propelled by a released spring force.

B

CVT0003

Valve Spring Compressor

1

Make sure to wear all necessary protective equip-

ment.

NOTICE

Keep all parts clean from contaminants.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

Contaminants may cause rapid wear and shortened

component life.

NOTICE

1. Inspect the valve springs for damage and for the

correct length. Refer to Speci fi cations, "Cylinder

Head Valves ”.

Plug the apertures for the push rods in the cylinder

head in order to prevent the entry of loose parts into

the engine.

2. Lubricate the valve stems with clean engine oil.

2. Position electronic unit injector clamp (1) on

Tooling (B). Install Tooling (B) into the electronic

unit injector sleeve. Tighten the bolt on the

electronic unit injector clamp in order to secure

Tooling (B).

3. Tighten the nut on Tooling (B) until valve keepers

(3) are loose on valves (2).

4. Remove valve keepers (3).

5. Loosen the nut in order to release the pressure

on Tooling (B). Remove electronic unit injector

clamp (1) and Tooling (B) from the electronic unit

injector sleeve.

g01411612

Illustration 36

6. Remove valve rotators (4).

3. If necessary, install new valve stem seals (8).

7. Remove outer valve springs (5) and inner valve

springs (6).

This document has been printed from SPI². Not for Resale


KENR6906

twenty one

Disassembly and Assembly Section

9. Loosen the nut in order to release the pressure

on Tooling (B). Remove electronic unit injector

clamp (1) and Tooling (B) from the electronic unit

injector sleeve.

10. Ensure that all of the valves are secured in place

by valve springs, valve rotators and valve keepers.

Rotate the crankshaft through approximately 45

degrees in order to clear the valves from the

piston. Lightly strike the top of the valves with a

soft faced hammer in order to ensure that the

valve keepers are properly installed.

End By:

a. Install the electronic unit injectors. Refer to

Disassembly and Assembly, "Electronic Unit

Injector-Install ".

i02754776

Inlet and Exhaust Valves-

Remove and Install

g01380893

Illustration 37

Improper assembly of parts that are spring loaded

can cause bodily injury.

Removal Procedure

To prevent possible injury, follow the established

assembly procedure and wear protective equip-

ment.

Table 10

Required Tools

Part

4. Install spring seats (7).

Tool

Number

Part Description

Qty

A

-

Valve Spring Compressor

1

5. Install inner valve springs (6) and outer valve

springs (5).

Start By:

6. Position valve rotators (4) on the valve springs.

a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head-Remove”.

7. Position electronic unit injector clamp (1) on

Tooling (B). Install Tooling (B) into the electronic

unit injector sleeve. Tighten the bolt on the

electronic unit injector clamp in order to secure

Tooling (B).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

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.

8. Tighten the nut on Tooling (B) in order to compress

the valve springs. Install valve keepers (3).

This document has been printed from SPI². Not for Resale


twenty two

KENR6906

Disassembly and Assembly Section

2. Carefully remove Tooling (A).

3. Remove valve rotator (2).

4. Remove outer valve spring (3) and inner valve

spring (4).

5. Repeat Steps 1 through 4 in order to remove the

remaining valve springs.

6. Remove spring seats (5).

7. Remove valve stem seals (7).

8. Remove valves (6) from the cylinder head.

g01395727

Illustration 38

Typical example

Installation Procedure

Table 11

Required Tools

Part

Tool

Number

Part Description

Qty

A

-

Valve Spring Compressor

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Inspect the valve springs for the correct length.

Refer to Speci fi cations, “Cylinder Head Valves”

for more information.

Note: Valve springs must be replaced in pairs for the

inlet valve or the exhaust valve of each cylinder.

2. Inspect the valves. Refer to Speci fi cations,

“Cylinder Head Valves” for more information.

g01392788

Illustration 39

Personal injury can result from being struck by

parts propelled by a released spring force.

Make sure to wear all necessary protective equip-

ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

1. Install Tooling (A) and compress the valve springs.

Remove valve keepers (1).

This document has been printed from SPI². Not for Resale


KENR6906

twenty three

Disassembly and Assembly Section

6. Install inner valve spring (4) and outer valve spring

(3).

7. Position valve rotator (2) on the valve springs.

8. Use Tooling (A) to compress the valve springs.

Install valve keepers (1).

9. Repeat Steps 6 through 8 in order to install the

remaining valve keepers.

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.

10. Carefully remove Tooling (A). Lightly strike the top

of the valve with a soft faced hammer in order to

ensure that valve keepers (1) are properly seated.

End By:

g01392788

Illustration 40

a. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head-Install”.

i02754778

Inlet and Exhaust Valve Guides

-Remove and Install

Removal Procedure

Table 12

Required Tools

g01395727

Illustration 41

Tool

Part Number

Part Description

Qty

Typical example

A

CVT0001

Valve Guide Driver

1

Start By:

The valve keepers can be thrown from the valve

when the valve spring compressor is released. En-

sure that the valve keepers are properly installed

on the valve stem. To help prevent personal injury,

keep away from the front of the valve keepers and

valve springs during the installation of the valves.

a. Remove the inlet and exhaust valves. Refer to

Disassembly and Assembly, "Inlet and Exhaust

Valves-Remove and Install ".

NOTICE

Keep all parts clean from contaminants.

3. Lubricate valves (6) with clean engine oil. Install

the valves to the cylinder head.

Contaminants may cause rapid wear and shortened

component life.

4. Install valve stem seals (7) to valves (6).

5. Install spring seats (5) to the cylinder head.

This document has been printed from SPI². Not for Resale


twenty four

KENR6906

Disassembly and Assembly Section

g01383260

g01383261

Illustration 42

Illustration 44

1. Use Tooling (A) and a hammer in order to remove

the valve guides from the cylinder head.

2. Use Tooling (A) and Tooling (B) to install valve

guides (1) in the cylinder head.

Installation Procedure

Note: Tooling (B) must be used in order to install the

valve guides to the correct height.

Table 13

Height (X) from the top of the valve guide to the

cylinder head surface ...... 35.00 ± 0.50 mm

(1.378 ± 0.020 inch)

Required Tools

Tool

A

Part Number

CVT0001

Part Description

Valve Guide Driver

Valve Guide Collar

Qty

1

For more information, refer to Speci fi cations,

"Cylinder Head Valves".

B

CVT0002

1

End By:

NOTICE

Keep all parts clean from contaminants.

a. Install the inlet and exhaust valves. Refer to

Disassembly and Assembly, "Inlet and Exhaust

Valves-Remove and Install ".

Contaminants may cause rapid wear and shortened

component life.

i02754779

Engine Oil Filter Base-

Remove

1. Lubricate the parent bores for the valve guides in

the cylinder head with clean engine oil.

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01383265

Illustration 43

This document has been printed from SPI². Not for Resale


KENR6906

25

Disassembly and Assembly Section

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.

Dispose of all fl uids according to local regulations and

mandates.

1. Place a suitable container below the engine oil

fi lter base in order to drain the engine oil.

g01401581

Illustration 46

9. Remove O-ring seals (8) and O-ring seal (9) from

engine oil fi lter base (5).

g01404137

Illustration 47

10. Remove O-ring seal (10) from the engine oil

pump.

g01396094

Illustration 45

2. Remove plug (8). Allow the engine oil to drain.

i02754781

Engine Oil Filter Base-

Disassemble

3. Remove engine oil fi lter (6) from engine oil fi lter

base (5). Remove the O-ring seal and remove the

fi lter element from the engine oil fi lter. Refer to

Operation and Maintenance Manual, "Engine Oil

and Filter-Change ”for more information.

4. Disconnect hose assembly (2) from engine oil

fi lter base (5).

Disassembly Procedure

5. Remove bolts (1) and (3).

Start By:

6. Remove bolts (4) in order to disconnect the tube

assembly from the engine oil pump.

a. Remove the engine oil fi lter base. Refer to

Disassembly and Assembly, "Engine Oil Filter

Base-Remove ".

7. Support the weight of the engine oil cooler. The

engine oil cooler weighs approximately 23 kg

(50 lb).

NOTICE

Keep all parts clean from contaminants.

8. Remove engine oil fi lter base (5) and remove the

joint.

Contaminants may cause rapid wear and shortened

component life.

This document has been printed from SPI². Not for Resale


26

KENR6906

Disassembly and Assembly Section

b. Remove spring (9).

c. Remove plunger (11).

Personal injury can result from being struck by

parts propelled by a released spring force.

Make sure to wear all necessary protective equip-

ment.

Follow the recommended procedure and use all

recommended tooling to release the spring force.

g01396108

Illustration 50

4. Follow Steps 4.a through 4.c in order to remove

the oil cooler bypass valve.

a. Remove plug (12) from engine oil fi lter base

(2). Remove O-ring seal (13) from plug (12).

g01380571

Illustration 48

b. Remove spring assembly (14).

c. Remove plunger (15).

1. If necessary, remove oil sampling valve (1) from

engine oil fi lter base (2). Remove the O-ring seal

from the oil sampling valve.

2. Follow Steps 2.a and 2.b in order to remove the

high pressure relief valve.

a. Remove bolt (7) from engine oil fi lter base (2).

b. Remove cap (6), spring (4), seat (5) and sleeve

(3) from engine oil fi lter base (2).

g01396110

Illustration 51

5. Follow Steps 5.a through 5.c in order to remove

the oil pump bypass valve.

a. Remove plug (16) from engine oil fi lter base

(2). Remove O-ring seal (18) from plug (16).

b. Remove spring (17).

c. Remove plunger (19).

g01396109

Illustration 49

3. Follow Steps 3.a through 3.c in order to remove

the oil filter bypass valve.

a. Remove plug (8) from engine oil fi lter base (2).

Remove O-ring seal (10) from plug (8).

This document has been printed from SPI². Not for Resale


KENR6906

27

Disassembly and Assembly Section

i02754782

Engine Oil Filter Base-

Assemble

Assembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

g01396108

Illustration 53

3. Follow Steps 3.a through 3.d in order to install the

oil cooler bypass valve.

Improper assembly of parts that are spring loaded

can cause bodily injury.

a. Lubricate spring assembly (14), and plunger

(15) with clean engine oil.

To prevent possible injury, follow the established

assembly procedure and wear protective equip-

ment.

b. Install spring assembly (14), and plunger (15)

into engine oil fi lter base (2).

c. Install a new O-ring seal (13) to plug (12).

1. Inspect the components for wear or damage.

Replace any components that are worn or

damaged.

d. Install plug (12) to engine oil fi lter base (2).

Tighten the plug to a torque of 100 N · m

(74 lb ft).

g01396110

Illustration 52

g01396109

Illustration 54

2. Follow Steps 2.a through 2.d in order to install the

oil pump bypass valve.

4. Follow Steps 4.a through 4.d in order to install the

oil filter bypass valve.

a. Lubricate plunger (19) and spring (17) with

clean engine oil.

a. Lubricate plunger (11) and spring (9) with clean

engine oil.

b. Install plunger (19) and spring (17) into engine

oil fi lter base (2).

b. Install plunger (11) and spring (9) into engine

oil fi lter base (2).

c. Install a new O-ring seal (18) to plug (16).

c. Install a new O-ring seal (10) to plug (8).

d. Install plug (16) to engine oil fi lter base (2).

Tighten the plug to a torque of 100 N · m

(74 lb ft).

d. Install plug (8) to engine oil fi lter base (2).

Tighten the plug to a torque of 100 N · m

(74 lb ft).

This document has been printed from SPI². Not for Resale


28

KENR6906

Disassembly and Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

1. Ensure that the engine oil fi lter base is clean and

free from damage. Clean the mating surfaces of

the engine oil pump and the cylinder block.

g01380571

Illustration 55

5. Follow Steps 5.a and 5.b in order to install the

high pressure relief valve.

a. Lubricate sleeve (3), seat (5), spring (4) and

cap (6) with clean engine oil.

b. Install sleeve (3), seat (5), spring (4), cap (6)

and bolt (7) to engine oil fi lter base (2). Tighten

the bolt to a torque of 12 Nm (105 lb in).

g01404137

Illustration 56

6. If necessary, install a new O-ring seal to oil

sampling valve (1) and install the oil sampling

valve to engine oil fi lter base (2). Tighten the oil

sampling valve to a torque of 24 Nm (18 lb ft).

2. Install a new O-ring seal (10) to the engine oil

pump.

End By:

a. Install the engine oil fi lter base. Refer to

Disassembly and Assembly, "Engine Oil Filter

Base-Install ".

i02754783

Engine Oil Filter Base-Install

Installation Procedure

g01401581

Illustration 57

Table 14

3. Install new O-ring seals (8) and (9) to engine oil

fi lter base (5).

Required Tools

Part

Tool

Number

Part Description

Qty

POWERPART

Threadlock and Nutlock

A

21820117

1

POWERPART

Special Lubricant

B

CV60889

1

This document has been printed from SPI². Not for Resale


KENR6906

29

Disassembly and Assembly Section

i02754784

Engine Oil Cooler-Remove

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE

Care must be taken to ensure that 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.

g01396094

Illustration 58

4. Apply Tooling (A) to the threads of bolts (7).

Dispose of all fl uids according to local regulations and

mandates.

5. Support the weight of the engine oil cooler. The

engine oil cooler weighs approximately 23 kg

(50 lb).

1. Drain the coolant from the cooling system into

a suitable container for storage or for disposal.

Refer to Operation and Maintenance Manual,

"Cooling System Coolant-Change".

6. Position a new joint and engine oil fi lter base (5)

on the cylinder block.

7. Install bolts (7). Tighten the bolts to a torque of

55 Nm (41 lb ft).

8. Connect the tube assembly to the engine oil pump

and install bolts (4). Tighten the bolts to a torque

of 28 Nm (21 lb ft).

9. Install bolts (1) and (3). Tighten the bolts to a

torque of 28 Nm (21 lb ft).

10. Connect hose assembly (2).

11. Install a new O-ring seal and a new fi lter element

to engine oil fi lter (6). Apply Tooling (B) to the

threads of the engine oil fi lter. Install the engine oil

fi lter to engine oil fi lter base (5). Use a suitable

tool with a 1/2 "square drive in order to tighten the

engine oil fi lters.

Refer to Operation and Maintenance Manual,

"Engine Oil and Filter-Change" for more

information.

g01401585

Illustration 59

2. Loosen the hose clamps and slide hose (4)

forward in order to disconnect the hose from the

engine oil cooler.

Install a new O-ring seal to plug (8). Install the

plug to fuel filter (6).

3. Follow Step 3.a through Step 3.c in order to

remove tube assembly (3).

a. Remove bolts (1) and joint (2) (not shown).

This document has been printed from SPI². Not for Resale


30

KENR6906

Disassembly and Assembly Section

b. Remove bolts (5) and tube assembly (3).

c. Remove O-ring seal (6) (not shown) from tube

assembly (3).

g01401595

Illustration 61

11. Remove O-ring seals (14) from engine oil fi lter

base (15).

i02754785

Engine Oil Cooler-Install

g01403771

Illustration 60

Installation Procedure

4. Attach a suitable lifting device to engine oil cooler

(9) in order to support the weight of the engine oil

cooler. The engine oil cooler weighs approximately

23 kg (50 lb).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

5. Remove bolts (12) and bolts (13).

6. Remove bolts (10).

1. Ensure that the oil cooler is clean and free from

damage or restriction. Clean the mating surfaces

of the cooler connections and the engine oil fi lter

base.

Note: The rear bolt needs only to be loosened in

order to remove connection (11).

7. Remove connection (11). Remove the O-ring seal

from the connection.

8. Remove bolts (8).

9. Carefully remove engine oil cooler (9).

10. Remove the O-ring seal from connection (7).

g01401595

Illustration 62

2. Install new O-ring seals (14) to engine oil fi lter

base (15).

This document has been printed from SPI². Not for Resale


KENR6906

31

Disassembly and Assembly Section

g01403771

g01401585

Illustration 63

Illustration 64

3. Install new O-ring seals to connections (7) and

(11).

9. Follow Step 9.a through Step 9.d in order to install

tube assembly (3).

4. Attach a suitable lifting device to engine oil

cooler (9). The weight of the engine oil cooler is

approximately 23 kg (50 lb).

a. Install a new O-ring seal (6) (not shown) to tube

assembly (3).

b. Install a new joint (2) and bolts (1) to tube

5. Position engine oil cooler (9) on the engine oil

fi lter base.

assembly (3).

c. Position tube assembly (3) on the engine and

tighten bolts (1) finger tight.

6. Install bolts (8). Tighten the bolts to a torque of

28 Nm (21 lb ft).

d. Install bolts (5). Tighten bolts (1) and fi ve to a

7. Position connection (11) on engine oil cooler (9)

and install bolts (10). Tighten the bolts to a torque

of 28 Nm (21 lb ft).

torque of 28 N · m (21 lb ft).

10. Connect hose (4) and tighten the hose clamps

securely.

8. Install bolts (12) and (13). Tighten the bolts to a

torque of 28 Nm (21 lb ft).

11. Fill the cooling system. Refer to Operation and

Maintenance Manual, "Cooling System Coolant

-Change ".

This document has been printed from SPI². Not for Resale


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