PERKINS 800D SERIES INDUSTRIAL ENGINE?Model UL?Service Repair Manual

KENR6241 August 2007

Disassembly and Assembly 800D Series Industrial Engine UK (Engine) UL (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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KENR6241

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) ....................................... 7 Fuel Injection Pump - Remove .............................. 9 Fuel Injection Pump - Remove (Fuel Injection Pumps With a Water Heated Cold Start Device) .............. 11 Fuel Injection Pump - Install (Fuel Injection Pumps With a Water Heated Cold Start Device) ............. 13 Fuel Injection Pump - Install ................................ 14 Fuel Injector - Remove and Install (Naturally Aspirated Engines) .............................................. 16 Fuel Injector - Remove and Install (Turbocharged Engines) .............................................................. 16 Turbocharger - Remove ........................................ 17 Turbocharger - Install ............................................ 19 Exhaust Manifold - Remove and Install ............... 20 Inlet Manifold - Remove and Install ..................... 21 Inlet and Exhaust Valve Springs - Remove and Install ................................................................... 23 Inlet and Exhaust Valves - Remove and Install .... 25 Engine Oil Filter Base - Remove and Install ........ 28 Engine Oil Cooler - Remove ................................. 29 Engine Oil Cooler - Install ..................................... 30 Engine Oil Relief Valve - Remove and Install ....... 31 Engine Oil Bypass Valve - Remove and Install ..... 32 Engine Oil Pump - Remove .................................. 33 Engine Oil Pump - Install ...................................... 34 Water Pump - Remove and Install ....................... 35 Water Temperature Regulator Housing - Remove and Install .................................................................. 37 Flywheel - Remove ............................................... 38 Flywheel - Install ................................................... 39 Crankshaft Rear Seal - Remove and Install ......... 40 Crankshaft Wear Sleeve (Rear) - Remove and Install ................................................................... 42 Flywheel Housing - Remove and Install .............. 43 Crankshaft Pulley - Remove and Install ............... 45 Crankshaft Front Seal - Remove and Install ......... 47 Front Cover - Remove and Install ......................... 48 Idler Gear - Remove and Install ............................ 48 Housing (Front) - Remove and Install ................... 51 Front Plate - Remove ............................................ 52 Front Plate - Install ................................................ 53 Crankcase Breather - Remove and Install (Turbocharged Engines) ..................................... 54 Valve Mechanism Cover - Remove and Install ..... 55 Rocker Shaft and Pushrod - Remove ................... 56 Rocker Shaft - Disassemble ................................ 57 Rocker Shaft - Assemble ..................................... 58 Rocker Shaft and Pushrod - Install ....................... 59 Cylinder Head - Remove ...................................... 60 Cylinder Head - Install .......................................... 62 Lifter Group - Remove and Install ......................... 64 Camshaft - Remove and Install ........................... 65

3 Table of Contents

Camshaft Gear - Remove and Install .................. 66 Engine Oil Pan - Remove and Install ................... 67 Balancer - Remove ............................................... 70 Balancer - Disassemble ........................................ 71 Balancer - Assemble ............................................. 72 Balancer - Install ................................................... 73 Pistons and Connecting Rods - Remove .............. 74 Pistons and Connecting Rods - Disassemble ....... 75 Pistons and Connecting Rods - Assemble ........... 77 Pistons and Connecting Rods - Install .................. 80 Connecting Rod Bearings - Remove (Connecting rods in position) ................................................... 81 Connecting Rod Bearings - Install (Connecting rods in position) ........................................................... 82 Crankshaft Main Bearings - Remove and Install (Crankshaft in position) ....................................... 83 Crankshaft - Remove ............................................ 87 Crankshaft - Install ................................................ 89 Crankshaft Gear - Remove and Install ................ 92 Bearing Clearance - Check ................................... 93 Coolant Temperature Sensor - Remove and Install ................................................................... 94 Engine Oil Pressure Sensor - Remove and Install ............................................................................. 94 Glow Plugs - Remove and Install ......................... 95 V-Belts - Remove and Install ................................ 97 Fan - Remove and Install ..................................... 97 Alternator - Remove and Install ........................... 98 Electric Starting Motor - Remove and Install ..... 100

Index Section Index ................................................................... 101

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4 Disassembly and Assembly Section

KENR6241

Disassembly and Assembly Section i02748528

Fuel Priming Pump and Fuel Filter Base - Remove and Install Removal Procedure

Illustration 1

g01324908

Typical example

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.

3. Drain fuel filter (4). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter/Water Seperator - Drain”.

4. Disconnect harness assembly (1) from fuel priming pump (2).

5. Disconnect the tube assemblies (not shown) from fuel filter base (3).

6. Remove bolts (5) and remove fuel filter base (3).

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.

1. Turn the fuel supply to the OFF position.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the assembly of the fuel priming pump and the fuel filter base is clean and free from damage. If necessary, replace any components that are damaged.

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

Illustration 2

g01324908

Typical example

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KENR6241

5 Disassembly and Assembly Section

2. Position fuel filter base (3) on the mounting bracket. Install bolts (5) to the fuel filter base.

Tighten the bolts to a torque of 35 N·m (26 lb ft).

3. Connect the tube assemblies for the fuel inlet and the fuel outlet (not shown) to fuel filter base (3).

4. If necessary, install a new fuel filter (4) to fuel filter base (3). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter/Water Seperator - Drain”.

5. Connect harness assembly (1) to fuel priming pump (2).

6. Turn the fuel supply to the ON position.

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

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

Illustration 3

g01332971

Typical example

i02748531

Fuel Injection Lines - Remove and Install (Naturally Aspirated Engines) Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 4

g01332972

Typical example

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

1. Turn the fuel supply to the OFF position.

2. If necessary, loosen the dipstick tube (not shown).

3. Disconnect hose (4) from tube assembly (6).

4. Disconnect fuel injection lines (1) from fuel injectors (3).

5. Disconnect fuel injection lines (1) from fuel injection pump (5).

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6 Disassembly and Assembly Section

KENR6241

Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened.

Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump.

6. Remove fuel injection lines (1).

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

8. Disconnect tube assembly (6) from fuel return line (2).

9. Remove banjo bolt (9) and sealing washers (10) from fuel injection pump (5).

10. Remove bolt (11) and remove tube assembly (6).

11. Remove nuts (7) from fuel injectors (3). Remove fuel return line (2) and sealing washers (8) from fuel injectors (3).

12. Use suitable caps in order to plug the open ports of the fuel injectors immediately.

Illustration 5

g01332971

Typical example

Installation Procedure Table 1

Required Tools Tool

Part Number

Part Description

Qty

A

27610294

Injector Pipe Nut Tool

1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 6

g01332972

Typical example

1. Remove the caps from fuel injectors (3) and install new sealing washers (8) to the fuel injectors.

Note: Washers (8) have two small holes. The position of the holes is not important.

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KENR6241

7 Disassembly and Assembly Section

2. Position fuel return line (2) onto fuel injectors (3).

3. Install nuts (7) onto each fuel injector. Tighten the nuts to a torque of 23 N·m (17 lb ft).

4. Position tube assembly (6) onto the engine.

Loosely connect the tube assembly to fuel return line (2).

5. Install banjo bolt (9) and new sealing washers (10) to fuel injection pump (5).

6. Install bolt (11). Tighten the bolt to a torque of 11 N·m (97 lb in).

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

1. Turn the fuel supply to the OFF position.

7. Tighten banjo bolt (9) to a torque of 18 N·m (13 lb ft). Tighten the nut to fuel return line (2) to a torque of 20 N·m (15 lb ft).

8. Remove the caps from the fuel injection pump.

Install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3).

9. Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N·m (22 lb ft).

Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened.

10. Connect hose (4) to tube assembly (6).

11. If necessary, tighten the dipstick tube (not shown) to a torque of 9 N·m (80 lb in).

12. Turn the fuel supply to the ON position.

13. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information. i02748529

Fuel Injection Lines - Remove and Install (Turbocharged Engines)

Illustration 7

g01332532

Typical example

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

Dispose of all fluids according to local regulations and mandates.

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8 Disassembly and Assembly Section

KENR6241

Installation Procedure Table 2

Required Tools Tool

Part Number

Part Description

Qty

A

27610294

Injector Pipe Nut Tool

1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 8

g01324910

Typical example

2. If necessary, loosen the dipstick tube (not shown).

3. Disconnect fuel injection lines (1) from fuel injectors (3).

4. Disconnect fuel injection lines (1) from fuel injection pump (5).

Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened.

Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump.

5. Remove clamps (4) and remove fuel injection lines (1).

Illustration 9

g01332532

Typical example

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

7. Disconnect tube assembly (6) from fuel injector (3). Disconnect tube assembly (6) from fuel injection pump (5). Remove bolts (7) and remove tube assembly (6).

8. Remove hoses (2) from fuel injectors (3).

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KENR6241

9 Disassembly and Assembly Section

i02748534

Fuel Injection Pump - Remove Removal Procedure Table 3

Required Tools Tool

Part Number

A

-

Part Description Combination Puller

Qty 1

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

Illustration 10

g01324910

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.

Typical example

1. Install hoses (2) to fuel injectors (3).

Dispose of all fluids according to local regulations and mandates.

2. Position tube assembly (6) onto the engine and install bolts (7). Tighten the bolts to a torque of 18 N·m (13 lb ft).

NOTICE Keep all parts clean from contaminants.

3. Connect tube assembly (6) to fuel injectors (3).

Connect tube assembly (6) to fuel injection pump (5).

4. Remove the caps from fuel injectors and from the fuel injection pump. Loosely install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3).

Contaminants may cause rapid wear and shortened component life.

1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

5. Install clamps (4). Tighten the clamps securely.

6. Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N·m (22 lb ft).

Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened.

7. If necessary, tighten the dipstick tube (not shown) to a torque of 9 N·m (80 lb in).

8. Turn the fuel supply to the ON position.

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

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10 Disassembly and Assembly Section

Illustration 11

KENR6241

g01335768

Illustration 13

g01375471

Typical example

Typical example

2. Remove bolts (4).

6. Loosen bolt (7).

3. Remove plate (2) from front housing (1).

7. Remove fasteners (8), bolt (10) and bracket (9).

4. Remove O-ring seal (3) from plate (2).

8. Support fuel injection pump (6) and remove bolt (7).

9. Remove the assembly of housing (5) and fuel injection pump (6).

Illustration 12

g01375914

Timing marks on the gears

5. Ensure that Timing marks (X) on the teeth of the gears are aligned or make temporary marks on the gears for installation purposes.

Illustration 14

g01335808

Typical example

10. Remove O-ring seal (13) from housing (5).

11. Loosen nut (11).

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KENR6241

11 Disassembly and Assembly Section

Note: Do not remove the nut at this time.

12. Use Tooling (A) to loosen gear (12). Remove nut (11) and gear (12).

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

13. If the original fuel injection pump will be installed, mark the flange of fuel injection pump (6) and housing (5). Remove nuts (15).

Note: Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check” for the correct method of setting the fuel injection pump timing after installation.

14. Remove housing (5) from fuel injection pump (6).

Remove O-ring seal (14) from housing (5). i02748532 g01366198

Fuel Injection Pump - Remove (Fuel Injection Pumps With a Water Heated Cold Start Device)

Illustration 15

Removal Procedure

4. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Table 4

Required Tools Tool

Part Number

A

-

Part Description Combination Puller

Typical example

2. Loosen the hose clamps and disconnect hoses (1) and (4) from fuel injection pump (2).

3. Loosen the hose clamps and remove hose (3) from fuel injection pump (2).

Qty 1

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

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

Dispose of all fluids according to local regulations and mandates.

Illustration 16

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

g01366190

Typical example

5. Remove bolts (8).

6. Remove plate (6) from front housing (5).

7. Remove O-ring seal (7) from plate (6).

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12 Disassembly and Assembly Section

Illustration 17

KENR6241

g01375914

Timing marks on the gears

8. Ensure that Timing marks (X) on the teeth of the gears are aligned or make temporary marks on the gears for installation purposes.

Illustration 19

g01375949

Typical example

13. Remove O-ring seal (16) from housing (9).

14. Loosen nut (14).

Note: Do not remove the nut at this time.

15. Use Tooling (A) to loosen gear (15). Remove nut (14) and gear (15).

16. If the original fuel injection pump will be installed, mark the flange of fuel injection pump (2) and housing (9). Remove nuts (18).

Note: Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check” for the correct method of setting the fuel injection pump timing after installation.

Illustration 18

g01375476

Typical example

17. Remove housing (9) from fuel injection pump (2).

Remove O-ring seal (17) from housing (9).

9. Loosen bolt (10).

10. Remove fasteners (11), bolt (13) and bracket (12).

11. Support fuel injection pump (2) and remove bolt (10).

12. Remove the assembly of housing (9) and fuel injection pump (2).

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KENR6241

13 Disassembly and Assembly Section

i02748536

Fuel Injection Pump - Install (Fuel Injection Pumps With a Water Heated Cold Start Device)

6. Install a new O-ring seal (16) to housing (9). Install gear (15) to fuel injection pump (2). Install nut (14) finger tight.

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Illustration 21

g01375476

Typical example

Illustration 22

g01375914

Timing marks on the gears Illustration 20

g01375949

Typical example

2. Ensure that the mating surfaces of housing (9) and fuel injection pump (2) are clean and free from damage.

3. Install a new O-ring seal (17) to housing (9).

4. Position housing (9) on fuel injection pump (2). If the original fuel injection pump is installed, ensure that the appropriate marks on the flange of the fuel injection pump and the housing are aligned.

Install nuts (18) finger tight.

7. Install the assembly of housing (9) and fuel injection pump (2) to the engine. Ensure that Timing marks (X) on the teeth of the gears are in the correct position. Install bolt (10) finger tight.

8. Position bracket (12) on fuel injection pump (2).

Install fasteners (11) and bolt (13) finger tight.

9. Tighten nut (14) to a torque of 90 N·m (66 lb ft).

Refer to Illustration 20.

5. Tighten nuts (18) to a torque of 18 N·m (13 lb ft).

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14 Disassembly and Assembly Section

KENR6241

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

16. Adjust the fuel injection pump timing. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check”.

End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. i02748535

Fuel Injection Pump - Install Illustration 23

g01366190

Typical example

Installation Procedure

10. Install a new O-ring seal (7) to plate (6).

NOTICE Keep all parts clean from contaminants.

11. Position plate (6) on front housing (5). Install bolts (8). Tighten the bolts to a torque of 18 N·m (13 lb ft).

Contaminants may cause rapid wear and shortened component life.

12. Tighten bolt (10) to a torque of 18 N·m (13 lb ft).

Tighten bolt (13) to a torque of 18 N·m (13 lb ft).

Tighten fasteners (11) to a torque of 35 N·m (26 lb ft). Refer to Illustration 21.

1. Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, “Finding Top Center Position for No. 1 Piston”.

Illustration 24

g01366198

Typical example

13. Install hose (3) to fuel injection pump (2). Tighten the hose clamps securely.

14. Connect hoses (1) and (4) to fuel injection pump (2). Tighten the hose clamps securely.

Illustration 25

g01335808

Typical example

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KENR6241

15 Disassembly and Assembly Section

2. Ensure that the mating surfaces of housing (5) and fuel injection pump (6) are clean and free from damage.

3. Install a new O-ring seal (14) to housing (5).

8. Position bracket (9) on fuel injection pump (6).

Install fasteners (8) and bolt (10) finger tight.

9. Tighten nut (11) to a torque of 90 N·m (66 lb ft).

Refer to Illustration 25.

4. Position housing (5) on fuel injection pump (6). If the original fuel injection pump is installed, ensure that the appropriate marks on the flange of the fuel injection pump and the housing are aligned.

Install nuts (15) finger tight.

5. Tighten nuts (15) to a torque of 18 N·m (13 lb ft).

6. Install a new O-ring seal (13) to housing (5). Install gear (12) to fuel injection pump (6). Install nut (11) finger tight.

Illustration 28

g01335768

Typical example

10. Install a new O-ring seal (3) to plate (2).

11. Position plate (2) on front housing (1). Install bolts (4). Tighten the bolts to a torque of 18 N·m (13 lb ft).

Illustration 26

g01375471

Typical example

12. Tighten bolt (7) to a torque of 18 N·m (13 lb ft).

Tighten bolt (10) to a torque of 18 N·m (13 lb ft).

Tighten fasteners (8) to a torque of 35 N·m (26 lb ft). Refer to Illustration 26.

13. Adjust the fuel injection pump timing. Refer to Systems Operation, Testing and Adjusting, “Fuel Injection Timing - Check”.

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

Illustration 27

g01375914

Timing marks on the gears

7. Install the assembly of housing (5) and fuel injection pump (6) to the engine. Ensure that Timing marks (X) on the teeth of the gears are in the correct position. Install bolt (7) finger tight.

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16 Disassembly and Assembly Section

KENR6241

i02748539

Fuel Injector - Remove and Install (Naturally Aspirated Engines)

Installation Procedure NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Clean the bore for the fuel injector in the cylinder head. Ensure that no debris enters the cylinder.

Clean the threads on the body of the fuel injector.

Removal Procedure 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 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 30

g01325773

Typical example

2. Install new seat washers (1) into the bore for the fuel injector in the cylinder head.

3. Install fuel injectors (2) into the cylinder head. Use a deep socket to tighten fuel injectors (2) to a torque of 59 N·m (44 lb ft).

End By: a. Install the fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Remove and Install”. i02748538

Illustration 29

g01325773

Fuel Injector - Remove and Install (Turbocharged Engines)

Typical example

1. Use a deep socket to remove fuel injectors (2) from the cylinder head.

2. Remove seat washers (1).

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

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