PERKINS 800 SERIES 800C INDUSTRIAL ENGINE (Model UF)Service Repair Manual

SENR9835-02 May 2006

Disassembly and Assembly 800C Industrial Engine UE (Engine) UF (Engine)

This document has been printed from SPI². Not for Resale

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

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SENR9835-02

Table of Contents Disassembly and Assembly Section Fuel Priming Pump and Fuel Filter Base - Remove and Install ........................................................... 4 Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines) .............................................. 5 Fuel Injection Lines - Remove and Install (Turbocharged Engines) ..................................... 6 Fuel Injection Pump - Remove ............................ 8 Fuel Injection Pump - Install ................................ 9 Turbocharger - Remove ........................................ 10 Fuel Injector - Remove (Turbocharged Engines) .. 11 Fuel Injector - Remove (Naturally Aspirated Engines) .............................................................. 11 Fuel Injector - Install (Turbocharged Engines) ...... 12 Fuel Injector - Install (Naturally Aspirated Engines) .............................................................. 12 Turbocharger - Install ............................................ 13 Exhaust Manifold - Remove and Install ............... 13 Inlet Manifold - Remove ....................................... 14 Inlet Manifold - Install ........................................... 15 Inlet and Exhaust Valve Springs - Remove and Install (Installed Cylinder Head) .................................... 15 Inlet and Exhaust Valves - Remove and Install .... 17 Inlet and Exhaust Valve Guides - Remove and Install ................................................................... 19 Inlet and Exhaust Valve Seat Inserts - Remove and Install ................................................................... 21 Engine Oil Filter Base - Remove and Install ........ 21 Engine Oil Cooler - Remove ................................. 22 Engine Oil Cooler - Install ..................................... 23 Engine Oil Relief Valve - Remove and Install ....... 24 Engine Oil Bypass Valve - Remove and Install ..... 24 Engine Oil Pump - Remove .................................. 25 Engine Oil Pump - Install ...................................... 26 Water Pump - Remove and Install ....................... 26 Water Temperature Regulator Housing - Remove and Install .................................................................. 27 Flywheel - Remove ............................................... 28 Flywheel - Install ................................................... 29 Crankshaft Rear Seal - Remove ........................... 30 Crankshaft Rear Seal - Install ............................... 30 Crankshaft Wear Sleeve (Rear) - Remove ........... 31 Crankshaft Wear Sleeve (Rear) - Install ............... 31 Flywheel Housing - Remove and Install .............. 32 Crankshaft Pulley - Remove and Install ............... 33 Crankshaft Front Seal - Remove .......................... 34 Crankshaft Front Seal - Install .............................. 34 Front Cover - Remove and Install ......................... 35 Idler Gear - Remove and Install ............................ 36 Housing (Front) - Remove .................................... 37 Housing (Front) - Install ........................................ 38 Crankcase Breather - Remove and Install ........... 38 Valve Mechanism Cover - Remove and Install ..... 39 Rocker Shaft and Pushrod - Remove ................... 40 Rocker Shaft - Disassemble ................................ 41 Rocker Shaft - Assemble ..................................... 41 Rocker Shaft and Pushrod - Install ....................... 42 Cylinder Head - Remove ...................................... 42

3 Table of Contents

Cylinder Head - Install .......................................... 43 Lifter Group - Remove and Install ......................... 45 Camshaft - Remove and Install ........................... 45 Camshaft Gear - Remove and Install .................. 47 Camshaft Bearings - Remove and Install ............ 47 Engine Oil Pan - Remove and Install ................... 48 Balancer - Remove (If equipped) .......................... 50 Balancer - Install ................................................... 52 Pistons and Connecting Rods - Remove .............. 54 Pistons and Connecting Rods - Disassemble ....... 55 Pistons and Connecting Rods - Assemble ........... 56 Pistons and Connecting Rods - Install .................. 57 Connecting Rod Bearings - Remove .................... 58 Connecting Rod Bearings - Install ........................ 59 Crankshaft Main Bearings - Remove .................... 59 Crankshaft Main Bearings - Install ........................ 61 Crankshaft - Remove ............................................ 63 Crankshaft - Install ................................................ 64 Crankshaft Gear - Remove and Install ................ 66 Bearing Clearance - Check ................................... 67 Coolant Temperature Switch - Remove and Install ................................................................... 68 Engine Oil Pressure Switch - Remove and Install ............................................................................. 69 Glow Plugs - Remove and Install (Naturally Aspirated Engines) .............................................................. 70 Glow Plugs - Remove and Install (Turbocharged Engines) .............................................................. 70 V-Belts - Remove and Install ................................ 71 Fan - Remove and Install ..................................... 72 Alternator - Remove .............................................. 73 Alternator - Install .................................................. 73 Electric Starting Motor - Remove and Install ....... 74

Index Section Index ..................................................................... 75

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4 Disassembly and Assembly Section

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Disassembly and Assembly Section

2. Disconnect the fuel return line from the fuel filter base.

3. Disconnect the harness assembly from the fuel priming pump.

i01967847

Fuel Priming Pump and Fuel Filter Base - Remove and Install

4. Remove the setscrews that hold fuel filter base (1). Remove the fuel filter base (1).

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Removal Procedure Note: Put identification marks on all hose assemblies and on all tube assemblies for installation purposes.

Plug all hose assemblies and tube assemblies.

This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Dispose of all fluids according to local regulations and mandates.

Illustration 2

g01002410

Note: The fuel filter is remotely mounted by the OEM and the torques for the mounting setscrews (1) may vary. Check with the OEM for the correct torque setting.

1. Position the fuel filter base (1) and install the setscrews. Tighten the setscrews evenly.

2. Connect the tube assemblies for the fuel inlet and the fuel outlet to the fuel filter base.

3. Connect the fuel return line to the fuel filter base.

4. Connect the harness assembly to the fuel priming pump.

5. Remove the air from the fuel system. Refer to Operations and Maintenance Manual, “Fuel System - Prime”.

Illustration 1

g01002410

1. Disconnect the tube assemblies for the fuel inlet and the fuel outlet from the fuel filter base.

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5 Disassembly and Assembly Section

i01972549

Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines)

Note: Use two spanner wrenches in order to remove each fuel injection line (1) at the fuel injection pump (5). Do not allow each union (4) for the fuel injection pump to turn.

3. Remove the fuel injection lines (1) from the engine.

Note: If necessary, loosen the clamps that tie the fuel injection lines together in order to maneuver the lines off the engine.

Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

Dispose of all fluids according to local regulations and mandates.

Illustration 4

g01024433

4. Disconnect the union nut (8). Remove the banjo bolt (11) and remove the sealing washers.

Remove the setscrew for the clamp (10). Remove the fuel return line (9).

5. Remove the nut (3) from each fuel injector.

Remove the fuel return line (7) from the engine.

Also remove the sealing washers (12) that are located under the fuel return line (7).

6. Remove the fuel inlet line (6) from the fuel injection pump (5).

Installation Procedure Illustration 3

g01024434

Note: If necessary, remove the dipstick tube.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Disconnect the fuel injection lines (1) from the fuel injector (2). Plug all openings immediately.

2. Disconnect the fuel injection lines (1) at the fuel injection pump (5).

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6 Disassembly and Assembly Section

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Note: If necessary, replace the sealing washer on the banjo bolt (11).

5. Position the fuel injection lines (1) on the engine.

6. Connect the fuel injection lines (1) at the fuel injection pump (5). Tighten the union nuts to a torque of 27 to 32 N·m (20 to 24 lb ft).

Note: Use two spanner wrenches in order to install the fuel injection lines (1) at the fuel injection pump (5). Do not allow the unions (4) for the fuel injection pump to turn.

7. Connect the fuel injection lines (1) to the fuel injectors (2). Tighten the union nuts to a torque of 27 to 32 N·m (20 to 24 lb ft).

8. If the clamps that tie the fuel injection lines together were loosened for removal purposes, tighten the clamps securely.

Illustration 5

g01024434

9. Install the fuel inlet line (6).

1. Install the new sealing washers (12) onto the fuel injectors (2). Locate the fuel return line (7) onto the fuel injectors (2).

Note: If the dipstick tube was removed, install the dipstick tube and tighten to 22 N·m (16 lb ft). i01968274

Fuel Injection Lines - Remove and Install (Turbocharged Engines) Removal Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 6

g01024433

2. Install the nuts (3) onto each fuel injector.

Tighten the nuts (3) to a torque of 20 to 24 N·m (15 to 18 lb ft).

3. Locate the fuel return line (7) onto the engine.

Connect the union nut (8). Install the banjo bolt (11).

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

Dispose of all fluids according to local regulations and mandates.

4. Tighten the banjo bolt (11) to a torque of 22 to 31 N·m (16 to 23 lb ft). Install the clamp bolt (10).

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Illustration 7

7 Disassembly and Assembly Section

g01021961

Note: If necessary, remove the dipstick tube.

1. Disconnect the fuel injection lines (1) from the fuel injectors (2). Plug all the openings immediately.

2. Disconnect the fuel injection lines (1) from the fuel injection pump (6). Plug all openings immediately.

Note: Use two spanner wrenches in order to remove the fuel injection lines (1) at the fuel injection pump (6). Do not allow the union (5) for the fuel injection pump to turn.

3. Remove the fuel injection lines (1) from the engine.

Note: If necessary, loosen the clamps that tie the fuel injection lines together in order to maneuver the lines off the engine.

Illustration 8

g01023626

4. Disconnect the fuel hoses (9) from the fuel return line (10) and disconnect the fuel hose (9) from the fuel injector (2). Disconnect the hose (13) that connects the individual injectors (2) to each other.

5. Remove the banjo bolt (12) and the sealing washers for the banjo bolt from the fuel injection pump (6).

6. Remove the clamping arrangement (11). Remove the fuel return line (10) from the engine.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

This document has been printed from SPI². Not for Resale

8 Disassembly and Assembly Section

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3. Position the fuel injection lines (1) on the engine.

4. Connect fuel injection lines (1) at the fuel injection pump (6). Tighten the union nuts to a torque of 27 to 32 N·m (20 to 24 lb ft).

Note: Use two spanner wrenches in order to install the fuel injection lines (1) at the fuel injection pump (6). Do not allow the union (5) for the fuel injection pump to turn.

5. Connect the fuel injection lines (1) to the fuel injectors (2). Tighten the union nuts to a torque of 27 to 32 N·m (20 to 24 lb ft).

6. Install the fuel inlet line to the banjo bolt (7) on the fuel injection pump (6).

7. If the clamps that tie the fuel injection lines together were loosened for removal purposes, tighten the clamps securely.

Illustration 9

g01021961

Note: Install the individual fuel hoses (13) between the fuel injectors. Check that the hose clamps (2) are secure.

Note: If the dipstick tube was removed, install the dipstick tube and tighten to 22 N·m (16 lb ft). i02295882

Fuel Injection Pump - Remove Removal Procedure Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. b. Remove the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”.

NOTICE Keep all parts clean from contaminants.

Illustration 10

g01023626

1. Install the fuel hose (9) onto the fuel injector (2).

Locate the fuel return line (10) onto the engine.

2. Connect the fuel hose (9) to the return line (10).

Install the clamp arrangement (11) and install the banjo bolt (12). Tighten banjo bolt (12) to a torque of 22 to 31 N·m (16 to 23 lb ft).

Note: If necessary, replace the sealing washers on the banjo bolt (12). Ensure that all the hose clamps are secure.

Contaminants may cause rapid wear and shortened component life.

Note: There are two types of fuel injection pump that may be installed on the engine. The pumps are manufactured by either Bosch or Denso and the same process is used to install both pumps.

1. Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

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9 Disassembly and Assembly Section

2. Disconnect the connection to the fuel shutoff solenoid.

i01976208

Fuel Injection Pump - Install Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 11

g01002553

3. Remove setscrew (5) that secures the fuel injection pump (1) to the support bracket. Remove the setscrew (4) from the flange.

1. Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

4. Remove the fuel injection pump (1) from the front housing.

5. Remove the nut (2) from the shaft of fuel injection pump (1).

Note: Ensure that the fuel injection pump is correctly supported before removing the nut for the fuel injection pump gear.

6. Use a suitable tool to remove the fuel injection pump gear (3).

7. Remove the O-ring seal from the flange.

Note: Check the condition of the O-ring seal for wear or damage. Replace the O-ring seal, if necessary.

8. If a Denzo fuel injection pump was installed on the engine, remove the two nuts from the studs that secure the flange to the fuel injection pump body.

Remove the joint. Discard the joint.

9. If a Bosch fuel injection pump was installed on the engine, remove the three nuts from the studs that secure the flange to the fuel injection pump body.

Remove the joint. Discard the joint.

Illustration 12

g01002553

2. Install a new joint on the flange. Position the flange on the fuel injection pump (1). If aBoschfuel injection pump was removed, install the three nuts that secure the flange to the fuel injection pump and tighten evenly to 22 N·m (16 lb ft).

If a Denso fuel injection pump was removed, install the two nuts that secure the flange to the fuel injection pump and tighten evenly to 22 N·m (16 lb ft).

3. Position the O-ring seal on the flange of the fuel injection pump.

Note: Ensure that the mating surfaces of the fuel injection pump gear and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut must turn freely until contact is made with the fuel injection pump gear.

4. Install fuel injection pump gear (3) to the shaft of the fuel injection pump (1).

Note: Be sure that the fuel injection pump is properly supported before installing the nut for the fuel injection pump gear.

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10 Disassembly and Assembly Section

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5. Install the nut (2) and tighten the nut to the following torque: Naturally aspirated engines ............. 59 to 69 N·m (43 to 51 lb ft) Turbocharged engines ..................... 83 to 98 N·m (61 to 72 lb ft) 6. Position the fuel injection pump (1) to the front housing of the engine. Install the setscrew (4) and tighten securely. Install the setscrew (5) for the support bracket and tighten evenly to 22 N·m (16 lb ft). g00999677

7. Install the connection to the fuel shutoff solenoid.

Illustration 13

End By:

1. Loosen the hose clamps (5) and remove the air inlet hose (3) from the inlet manifold and from the air pipe (2).

a. Install the front cover. Refer to Disassembly and Assembly, “Front Cover - Remove and Install”. b. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.

2. Remove the setscrews (4). Remove the air pipe (2) and the gasket (1) from the turbocharger compressor housing.

i01974273

Turbocharger - 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, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

Illustration 14

g01025765

3. Remove the banjo bolt (6) and the sealing washers (7). Remove the oil supply tube assembly (8) from the turbocharger (20).

4. Remove the setscrews (14). Remove the oil drain tube assembly (13) and the joint (15) from the turbocharger.

5. If necessary, loosen the hose clamps (11) and remove the setscrew (12) in order to remove the oil supply tube assembly (8) and the oil drain tube assembly (13) from the cylinder block.

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11 Disassembly and Assembly Section

6. If necessary, remove studs (19) from the turbocharger housing.

1. Remove the setscrew (1). Remove the clamp (2) from the fuel injector (3).

7. Remove the locknuts (18). Remove the turbocharger (20) and the joint (17) from the exhaust manifold.

2. Remove the fuel injector (3) and sealing washer (4) from the cylinder head.

8. If necessary, remove the studs (16) from the exhaust manifold.

9. Plug the oil supply and the oil drain ports of the turbocharger. i01974250

Fuel Injector - Remove (Turbocharged Engines)

3. Repeat the procedure in order to remove the remaining fuel injectors. i01974249

Fuel Injector - Remove (Naturally Aspirated Engines) Removal Procedure Start By:

Removal Procedure

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

Start By: a. Remove the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

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

Dispose of all fluids according to local regulations and mandates.

Dispose of all fluids according to local regulations and mandates.

Illustration 16

Illustration 15

g01002464

g01002452

1. Remove the fuel injector (1) and the sealing washer (2) from the cylinder head.

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12 Disassembly and Assembly Section

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2. Repeat the procedure in order to remove the remaining fuel injectors. i01974251

Fuel Injector - Install (Turbocharged Engines)

i01976055

Fuel Injector - Install (Naturally Aspirated Engines) Installation Procedure NOTICE Keep all parts clean from contaminants.

Installation Procedure

Contaminants may cause rapid wear and shortened component life.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 18

g01002452

1. Position the washer (2) onto the fuel injector (1).

Illustration 17

g01002464

1. Position the sealing washer (4) onto the fuel injector (3).

2. Position the fuel injector (3) into the cylinder head.

3. Position the clamp (2) onto the fuel injector.

Install the setscrew (1) and tighten to a torque of 21 to 23 N·m (16 to 17 lb ft).

4. Repeat the procedure in order to install the remaining fuel injectors.

2. Install the fuel injector (1) into the cylinder head and tighten to a torque of 53 to 65 N·m (40 to 48 lb ft).

3. Repeat the procedure in order to install the remaining fuel injectors (1).

End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.

End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”.

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13 Disassembly and Assembly Section

i01978805

Turbocharger - Install

9. If necessary, install oil supply tube assembly (11) to the cylinder block and tighten the bolts evenly.

Install bolt (17) and the clamp in order to secure the two tube assemblies (11) and (15) together.

10. If necessary, install studs (7) in the turbocharger housing.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Clean the mating surfaces of the exhaust manifold and the turbocharger. Clean the mating surfaces of the turbocharger and the oil supply tube assembly and the oil drain tube assembly.

2. Ensure that the turbocharger inlet and outlet ports are clean and free from restrictions. The turbocharger shaft must rotate freely.

Illustration 20

g00999677

11. Install gasket (1) and air pipe (2) on the turbocharger compressor housing. Install bolts (4) and tighten evenly to 22 N·m (16 lb ft).

12. Install air inlet hose (3) on the air inlet manifold and on air pipe (2). Tighten hose clamps (5) securely. i01978806

Exhaust Manifold - Remove and Install Illustration 19

g00999706

3. If necessary, install studs (13) in the exhaust manifold. Install gasket (10) over the studs.

Note: Do not use any sealant on the gasket.

4. Position turbocharger (6) on the exhaust manifold.

5. Apply a suitable anti-seize compound to the threads of studs (13). Install locknuts (9) and tighten evenly.

6. Position a new gasket (14) and oil drain tube assembly (15) on the bottom of the turbocharger.

Tighten bolts (16) evenly to 22 N·m (16 lb ft).

7. If necessary, install oil drain tube assembly (15) to the cylinder block. Tighten hose clamps (18) securely.

8. Position new sealing washers (12) and oil supply tube assembly (11) on the turbocharger. Install banjo bolt(8) and tighten securely.

Removal Procedure Start By: a. Remove the turbocharger, if equipped. Refer to Disassembly and Assembly, “Turbocharger Remove”.

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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14 Disassembly and Assembly Section

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2. Position the exhaust manifold (2) on the guide studs.

3. Ensure that all of the setscrews (1) are clean.

Install the setscrews (1) into the holes that do not have a guide stud. Remove the guide stud and install the remainder of the setscrews (1).

4. Begin at the center of the exhaust manifold and work toward the ends. Tighten the setscrews to the following torque: Naturally aspirated engines ............. 15 to 22 N·m (11 to 16 lb ft) Illustration 21

g00998953

1. Remove the setscrews (1) that secure the exhaust manifold (2) to the cylinder head. Begin at the ends of the exhaust manifold (2) and work toward the center.

2. Remove the exhaust manifold (2) from the cylinder head.

3. Remove the joint (3) from the cylinder head.

Discard the joint.

Turbocharged engines ..................... 28 to 33 N·m (21 to 24 lb ft) End By: a. Install the turbocharger, if equipped. Refer to Disassembly and Assembly, “Turbocharger Install”. i02001084

Inlet Manifold - Remove

Installation Procedure NOTICE Keep all parts clean from contaminants.

Removal Procedure

Contaminants may cause rapid wear and shortened component life.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. If the engine is equipped with a turbocharger, remove the air inlet hose that is above the valve mechanism cover. Refer to Disassembly and Assembly, “Turbocharger - Remove”.

Illustration 22

g01000656

1. Clean the flange face of the cylinder head. Install a guide stud “M8 x 1.25 by 100 mm” into the cylinder in order to align with the holes (X). Position a new joint (3) on the guide studs.

Note: Do not use any sealant on the joint.

Illustration 23

g01001495

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15 Disassembly and Assembly Section

2. Remove the setscrews (4) from the inlet manifold (3).

3. Remove the inlet manifold (3) and the gasket (1) from the cylinder head. Discard the gasket.

i01978832

Inlet and Exhaust Valve Springs - Remove and Install (Installed Cylinder Head)

4. If necessary, remove the setscrews for the air inlet elbow (2). Remove the air inlet elbow (2) and the gasket from the inlet manifold (3).

Removal Procedure i02001105

Table 1

Inlet Manifold - Install

Required Tools Part Number

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that all the mounting surfaces are clean and free from debris.

Part Description

Qty

21825666

Valve Spring Compressor

1

21825931

Stud Adapter

1

21825932

Setscrew Adapter

1

27610261

Installer for the Valve Stem Seal

1

Start By: a. Remove the fuel injectors. Refer to Disassembly and Assembly, “Fuel Injector - Remove (Naturally Aspirated Engines) ” and Disassembly and Assembly, “Fuel Injector - Remove (Turbocharged Engines) ”. b. Remove the rocker shaft assembly. 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.

Illustration 24

g01001495

2. If necessary, position a new gasket and the air inlet elbow (2) onto the inlet manifold (3). Install the setscrews and tighten evenly.

3. Position the gasket (1) onto the back of the inlet manifold (3).

Note: The following procedure is for the removal of the inlet and exhaust valve springs without removing the cylinder head. Perform the removal and installation procedures for one cylinder at a time in order to avoid dropping a valve into the engine.

4. Position the inlet manifold (3) onto the cylinder head.

Note: Before you begin the removal of the valve springs, refer to Specifications, “Cylinder Head Valves” for appropriate information on the valve springs.

5. Install the setscrews (4) and tighten evenly.

1. Ensure that the piston is at the top center position.

6. If the engine is equipped with a turbocharger, install the air inlet hose that is above the valve mechanism cover. Refer to Disassembly and Assembly, “Turbocharger - Install”.

Note: If the rocker shaft assembly has been removed, use the following procedure in order to find the top center position. Go to Step 2 if the rocker arm assembly is installed.

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16 Disassembly and Assembly Section

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

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

3. Carefully release all the pressure on the Valve Spring Compressor . Remove the valve spring retainer (3) and the valve spring (4).

4. If it is necessary, use a suitable tool to remove the valve stem seals.

Note: If you are replacing all of the valve springs, the procedure can be done on two cylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, and on cylinder 2 and cylinder 3.

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

Installation Procedure Table 2 Illustration 25

g01038636

Required Tools Part Number

Part Description

Qty

21825666

Valve Spring Compressor

1

Personal injury can result from being struck by parts propelled by a released spring force.

21825931

Adapter for the stud

1

Make sure to wear all necessary protective equipment.

21825932

Follow the recommended procedure and use all recommended tooling to release the spring force. a. Install the 21825666 Valve Spring Compressor with the 21825931 Adapter for the Valve Spring or the 21825932 Adapter for the Setscrew . b. Compress the valve spring in order to open the valve. c. Turn the crankshaft until the piston touches the valve. d. Continue to turn the crankshaft and release the pressure of the Valve Spring Compressor until the piston is at the Top Center position.

27610261

Adapter for the setscrew 1 Installer for the Valve Stem Seal

1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

1. Use the 27610261 Installer for the Valve Stem Seals to install the new valve stem seals into the cylinder head (not shown).

2. Place the new valve spring (4) into position.

2. Use the Valve Spring Compressor in order to compress the valve spring (4). Use a suitable magnetic tool to remove the valve caps (1) and the valve keepers (2).

This document has been printed from SPI². Not for Resale

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