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 .................................... 7

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  ................................  64

Rocker Shaft - Assemble  ..................................... 65

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

Cylinder Head - Remove ......................................  67

Cylinder Head - Install ..........................................  70

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

Lifter Group - Disassemble ................................... 73

Lifter Group - Assemble ........................................ 73

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

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

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

Camshaft Gear - Remove and Install  ..................  78

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

Camshaft Bearings - Install ................................... 79

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 ................................... 97

Atmospheric Pressure Sensor  - Remove and

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

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

Inlet and Exhaust Valve  Guides - Remove and

Install ................................................................... 23

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 ................................ 33

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 ..................................  54

Housing (Front) - Remove ....................................  55

Housing (Front) - Install ........................................  55

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 ......................................... 106

Fan - Remove and Install ...................................  107

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

Fan Drive - Disassemble  ...................................  108

Fan Drive - Assemble  ......................................... 110

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

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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 fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids 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 filter 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 filter 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 N·m (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 filter 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 filters (9) and (10). Remove  the

O-ring seals and the fuel filter elements from the

fuel filters. 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 fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

7.  Remove bolts (6). Remove fuel filter base (8).

i02754756

Fuel Filter Base - Disassemble

Dispose of all fluids 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 filter 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 filter

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 filter

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 filter

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).

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KENR6906

7

Disassembly and  Assembly Section

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

fuel filter 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

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

torque of 35 N·m (26 lb ft).

4.  Remove fuel check valve (10) from fuel filter 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 filter 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

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

connections.

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

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

6.  Install fuel temperature sensor (2) to fuel filter

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 filter  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 filter 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 filter base is clean and free

from damage. If necessary, replace the fuel filter

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 filter 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 N·m (11 lb ft).

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

(7) and (8). Install the connections to  fuel filter

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 N·m (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 fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids 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 filter base (8) onto the  mounting

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

torque of 55 N·m (41 lb ft).

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

2.  Install new O-ring seals  and new fuel filter

elements to fuel filters (9) and (10). Apply Tooling

(A) to the threads of the fuel filters. Install the fuel

filters to fuel filter base (8). Tighten the fuel filters.

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 filters (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).

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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 filter

base in order to drain fuel from the cylinder head.

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

55 N·m (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 identification 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 N·m (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 N·m (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 filter 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 N·m (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 N·m (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 fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids 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 filter 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 N·m (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 N·m (21 lb ft).

5.  If necessary, remove the taperlock studs from the

cylinder head.

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

filter 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 N·m

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

compressor housing to 18 N·m (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 N·m (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 N·m (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 N·m (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 Specifications, “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

21

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

 

22

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 Specifications, “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  Specifications,

“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

23

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

 

24

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  Specifications,

“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 fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

1.  Place a suitable container below the engine oil

filter 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 filter 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 filter (6) from engine oil filter

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

filter element from the engine oil filter. Refer  to

Operation and Maintenance Manual, “Engine Oil

and Filter - Change” for more information.

4.  Disconnect hose assembly (2) from engine oil

filter 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 filter  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 filter 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 filter 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 filter 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 filter base (2).

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

(3) from engine oil filter 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 filter 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 filter 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 filter 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 filter 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 filter base (2).

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

oil filter 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 filter base (2).

Tighten the plug  to a torque of 100  N·m

(74 lb ft).

d. Install  plug (8) to engine oil filter 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 filter 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 filter base (2). Tighten

the bolt to a torque of 12 N·m (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 filter base (2). Tighten the oil

sampling valve to a torque of 24 N·m (18 lb ft).

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

pump.

End By:

a.  Install the engine oil  filter 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

filter 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 fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

g01396094

Illustration 58

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

Dispose of all fluids 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 filter base (5)

on the cylinder block.

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

55 N·m (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 N·m (21 lb ft).

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

torque of 28 N·m (21 lb ft).

10. Connect hose assembly (2).

11. Install a new O-ring seal and a new filter element

to engine oil filter (6). Apply  Tooling (B) to the

threads of the engine oil filter. Install the engine oil

filter to engine oil filter base (5). Use a  suitable

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

engine oil filters.

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 filter

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 filter

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 filter

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

filter 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 N·m (21 lb ft).

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

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

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

of 28 N·m (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 N·m (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