Perkins 1106c e70ta and 1106d e70ta industrial engine （model pw）service repair manual

UENR0682 November 2013

Disassembly and Assembly 1106C-E70TA and 1106D-E70TA Industrial Engines PV (Engine) PW (Engine)

This document is 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.

This document is printed from SPI². Not for RESALE

UENR0682

3 Table of Contents

Table of Contents Disassembly and Assembly Section Fuel Priming Pump - Remove and Install (Mechanical Priming Pump).............. .............. 5 Fuel Priming Pump - Remove and Install (Electric Fuel Lift Pump (EFLP)) ........... .......... 6 Flow Control Valve - Remove and Install..... ..... 8 Fuel Filter Base - Remove and Install....... ...... 10 Water Separator and Fuel Filter (Primary) Remove and Install .................... ................... 13 Fuel Manifold (Rail) - Remove and Install.... ... 15 Relief Valve (Fuel) - Remove and Install..... .... 17 Fuel Injection Lines - Remove ............ ............ 19 Fuel Injection Lines - Install .............. .............. 22 Fuel Injection Pump - Remove ............ ........... 26 Fuel Injection Pump - Install .............. ............. 28 Fuel Injection Pump Gear - Remove ....... ....... 32 Fuel Injection Pump Gear - Install ......... ......... 34 Electronic Unit Injector - Remove .......... ......... 36 Electronic Unit Injector - Install ............ ........... 38 Turbocharger - Remove (Turbocharger for Top Mounted Engines)..................... .................... 41 Turbocharger - Remove (Turbocharger for Side Mounted Engines)..................... .................... 43 Exhaust Manifold - Remove and Install (Top Mounted Exhaust Manifold)............. ............. 44 Exhaust Manifold - Remove and Install (Side Mounted Exhaust Manifold)............. ............. 47 Wastegate Solenoid - Remove and Install... ... 49 Turbocharger - Install (Turbocharger for Top Mounted Engines)..................... .................... 51 Turbocharger - Install (Turbocharger for Side Mounted Engines)..................... .................... 53 Exhaust Elbow - Remove and Install....... ....... 56 Inlet Manifold - Remove and Install ........ ........ 57 Inlet and Exhaust Valve Springs - Remove and Install............................... .............................. 61 Inlet and Exhaust Valves - Remove and Install 65 Engine Oil Filter Base - Remove and Install .. . 68 Engine Oil Cooler - Remove (Engine Oil Cooler with a Low Mounted Filter Base).......... ......... 69 Engine Oil Cooler - Remove (Engine Oil Cooler with a High Mounted Filter Base)......... ......... 70 Engine Oil Cooler - Install (Engine Oil Cooler with a Low Mounted Filter Base).......... ......... 71 Engine Oil Cooler - Install (Engine Oil Cooler with a High Mounted Filter Base)......... ......... 73 Engine Oil Pump - Remove .............. .............. 76

Engine Oil Pump - Install ................ ................ 77 Water Pump - Remove .................. ................. 78 Water Pump - Install .................... ................... 79 Water Temperature Regulator - Remove and Install............................... .............................. 81 Flywheel - Remove (Equipped with Rear Power Take-Off) ............................ ........................... 82 Flywheel - Remove..................... .................... 83 Flywheel - Install....................... ...................... 84 Flywheel - Install (Equipped with Rear Power Take-Off) ............................ ........................... 85 Crankshaft Rear Seal - Remove........... .......... 86 Crankshaft Rear Seal - Install............. ............ 87 Flywheel Housing - Remove and Install (Flywheel Housing that is Equipped with Rear Power Take-Off) ...................... ...................... 88 Flywheel Housing - Remove and Install (Standard Housing).................... ................... 92 Flywheel Housing - Remove and Install (Type A and Type B Wet Back End Housing)....... ...... 95 Rear Power Take-Off (RPTO) - Remove ... ... 100 Rear Power Take-Off (RPTO) - Install ..... ..... 102 Vibration Damper and Pulley - Remove .... ... 105 Vibration Damper and Pulley - Install ............ 106 Crankshaft Front Seal - Remove and Install. 107 Crankshaft Front Seal - Remove and Install (Crankshaft Front Seal for Heavy Duty Front Cover) ............................. ............................ 108 Front Cover - Remove and Install......... .........110 Front Cover - Remove and Install (Heavy Duty Front Cover)......................... ........................111 Gear Group (Front) - Remove and Install (Heavy Duty Gear Group (Front))............... ..............112 Gear Group (Front) - Remove and Install ... .. 121 Idler Gear - Remove ................... .................. 125 Idler Gear - Install ..................... .................... 128 Housing (Front) - Remove .............. .............. 131 Housing (Front) - Remove (Heavy Duty Housing (Front))............................ ............................ 132 Housing (Front) - Install ................ ................ 133 Housing (Front) - Install (Heavy Duty Housing (Front))............................ ............................ 136 Accessory Drive - Remove and Install (Accessory Drive SAE "B") ............. ............ 139 Accessory Drive - Remove and Install (Accessory Drive SAE "A") ............. ............ 142 Crankcase Breather - Remove (Unfiltered Breather)........................... .......................... 144 Crankcase Breather - Remove (Filtered Breather)........................... .......................... 145

This document is printed from SPI². Not for RESALE

4

UENR0682

Table of Contents

Crankcase Breather - Install (Unfiltered Breather)........................... .......................... 146 Crankcase Breather - Install (Filtered Breather)........................... .......................... 146 Valve Mechanism Cover - Remove and Install.............................. ............................. 148 Valve Mechanism Cover Base - Remove and Install.............................. ............................. 150 Rocker Shaft and Pushrod - Remove...... ..... 155 Rocker Shaft - Disassemble ............. ............ 157 Rocker Shaft - Assemble............... ............... 158 Rocker Shaft and Pushrod - Install........ ....... 159 Cylinder Head - Remove ............... ............... 162 Cylinder Head - Install ................. ................. 166 Lifter Group - Remove and Install......... ........ 172 Camshaft - Remove and Install .......... .......... 174 Camshaft Gear - Remove and Install ...... ..... 175 Camshaft Bearings - Remove and Install ... .. 180 Engine Oil Pan - Remove (Aluminum Oil Pan) .............................. .............................. 181 Engine Oil Pan - Install (Aluminum Oil Pan) 182 Piston Cooling Jets - Remove and Install... .. 185 Pistons and Connecting Rods - Remove... ... 187 Pistons and Connecting Rods - Disassemble 188 Pistons and Connecting Rods - Assemble .. . 190 Pistons and Connecting Rods - Install..... ..... 192 Connecting Rod Bearings - Remove (Connecting rods in position)...................... ..................... 193 Connecting Rod Bearings - Install (Connecting rods in position)...................... ..................... 194 Crankshaft Main Bearings - Remove and Install (Crankshaft in Position) ............... ............... 196 Crankshaft - Remove.................. .................. 200 Crankshaft - Install.................... .................... 203 Crankshaft Timing Ring - Remove and Install 206 Crankshaft Gear - Remove and Install ..... .... 207 Refrigerant Compressor - Remove and Install.............................. ............................. 209 Bearing Clearance - Check ............. ............. 212 Coolant Temperature Sensor - Remove and Install.............................. ............................. 213 Engine Oil Pressure Sensor - Remove and Install.............................. ............................. 214 Camshaft Position Sensor - Remove and Install.............................. ............................. 215 Crankshaft Position Sensor - Remove and Install.............................. ............................. 216 Fuel Pressure Sensor - Remove and Install. 217 Boost Pressure Sensor - Remove and Install 219 Inlet Air Temperature Sensor - Remove and Install.............................. ............................. 220

Glow Plugs - Remove and Install......... ......... 220 Alternator Belt - Remove and Install ....... ...... 222 Idler Pulley - Remove and Install (Grooved Idler Pulley)............................. ............................ 223 Idler Pulley - Remove and Install (Flat Idler Pulley)............................. ............................ 224 Belt Tensioner - Remove and Install....... ...... 225 Fan - Remove and Install............... ............... 227 Fan Drive - Remove and Install .......... .......... 228 ECM Mounting Bracket - Remove and Install 228 Electronic Control Module - Remove and Install.............................. ............................. 231 Alternator - Remove................... ................... 233 Alternator - Install..................... ..................... 235 Electric Starting Motor - Remove and Install 239 Air Compressor - Remove and Install (Twin Cylinder Air Compressor) ............. .............. 240 Air Compressor - Remove and Install (Single Cylinder Air Compressor) ............. .............. 246

Index Section Index............................... .............................. 253

This document is printed from SPI². Not for RESALE

5

UENR0682

Disassembly and Assembly Section

Disassembly and Assembly Section i05495473

Fuel Priming Pump - Remove and Install (Mechanical Priming Pump) Removal Procedure Table 1 Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

1. Turn the fuel supply to the OFF position.

Illustration 1

g03411153

2. The fuel priming pump can be installed in any location on a machine. Ref to the Original Equipment Manufacture (OEM) for the correct location.

3. Make temporary identification marks on tube assemblies in order to show the correct position of the tube assemblies.

4. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

5. Disconnect tube assembly (2) and tube assembly (3) from the assembly of primary fuel filter (4).

6. Use Tooling (A) in order to plug the tube assemblies. Use Tooling (A) in order to cap the connections on the primary fuel filter.

7. Disconnect the OEM harness assembly from the connection on harness assembly (5) for water in fuel sensor (6).

8. Remove bolts (1) and remove the assembly of primary fuel filter (4) from the mounting. Support the primary fuel filter as the bolts are removed.

9. If necessary, disassemble the assembly of primary fuel filter (5). Ref to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure.

This document is printed from SPI². Not for RESALE

6

UENR0682

Disassembly and Assembly Section

Installation Procedure (Manual Priming Pump) NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that the fuel priming pump is clean and free from wear and damage. If necessary, replace the fuel priming pump.

2. If necessary, assemble the assembly of primary fuel filter (5). Ref to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure.

For M10 8.8 graded bolts, tighten the bolts to a torque of 44 N·m (32 lb ft).

For different graded bolts, refer to the OEM for the correct torque values.

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

5. Remove plug from tube assembly (2). Remove cap from the connection on the primary fuel filter.

6. Connect tube assembly (2) to primary fuel filter (4).

7. Remove plug from tube assembly (3). Remove cap from the connection on the primary fuel filter.

8. Connect tube assembly (3) to primary fuel filter (4).

9. Connect the OEM harness assembly to the connection on harness assembly (6) for water in fuel sensor (5).

10. Turn the fuel supply to the ON position.

11. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”for the correct procedure. i05495472

Fuel Priming Pump - Remove and Install (Electric Fuel Lift Pump (EFLP)) Removal Procedure Table 2 Required Tools

Illustration 2

g03411153

Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

3. Position the assembly of primary fuel filter (4) onto the mounting.

4. Install bolts (2) to the assembly of primary fuel filter (3).

For M8 8.8 graded bolts, tighten the bolts to a torque of 22 N·m (195 lb in).

This document is printed from SPI². Not for RESALE

7

UENR0682

Disassembly and Assembly Section

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

1. Turn the fuel supply to the OFF position.

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

5. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

6. Disconnect tube assembly (3) and tube assembly (4) from the assembly of primary fuel filter (5).

7. Use Tooling (A) in order to plug the tube assemblies. Use Tooling (A) in order to cap the connections on the primary fuel filter.

8. Disconnect the OEM harness assembly from the connection on harness assembly (7) for water in fuel sensor (6).

9. Disconnect the OEM harness assembly from the connection on harness assembly (1).

10. Remove bolts (2) and remove the assembly of primary fuel filter (5) from the mounting. Support the primary fuel filter as the bolts are removed.

11. If necessary, disassemble the assembly of primary fuel filter (5). Ref to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) - Remove and Install” for the correct procedure.

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that the fuel priming pump is clean and free from wear and damage. If necessary, replace the fuel priming pump.

Illustration 3

g03411118

2. If necessary, assemble the assembly of primary fuel filter (5). Ref to Disassembly and Assembly, “Water Separator and Fuel Filter (Primary) Remove and Install” for the correct procedure.

3. The fuel priming pump can be installed in any location on a machine. Ref to the Original Equipment Manufacture (OEM) for the correct location.

4. Make temporary identification marks on tube assemblies in order to show the correct position of the tube assemblies.

This document is printed from SPI². Not for RESALE

8

UENR0682

Disassembly and Assembly Section

11. Turn the fuel supply to the ON position.

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

13. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”for the correct procedure. i05495389

Flow Control Valve - Remove and Install Removal Procedure Table 3 Required Tools Illustration 4

g03411118

3. Position the assembly of primary fuel filter (3) onto the mounting.

Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

4. Install bolts (2) to the assembly of primary fuel filter (3).

For M8 8.8 graded bolts, tighten the bolts to a torque of 22 N·m (195 lb in).

For M10 8.8 graded bolts, tighten the bolts to a torque of 44 N·m (32 lb ft).

For different graded bolts, refer to the OEM for the correct torque values.

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

5. Remove plug from tube assembly (3). Remove cap from the connection on the primary fuel filter.

6. Connect tube assembly (3) to primary fuel filter (5).

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

7. Remove plug from tube assembly (4). Remove cap from the connection on the primary fuel filter.

1. Turn the fuel supply to the OFF position.

8. Connect tube assembly (4) to primary fuel filter (5).

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

9. Connect the OEM harness assembly to the connection on harness assembly (7) for water in fuel sensor (6).

3. If necessary, remove fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base Remove and Install” for the correct procedure.

10. Connect the OEM harness assembly to the connection on harness assembly (1).

This document is printed from SPI². Not for RESALE

UENR0682

9 Disassembly and Assembly Section

4. If necessary, remove crankcase breather canister filter. Refer to Operation and Maintenance Manual, “Engine Crankcase Breather Element - Replace” for the correct procedure.

Illustration 5

Illustration 6

g03411798

Illustration 7

g03411799

g03411798

5. Clean the area around flow control valve (3) and fuel injection pump (1). Ensure that the area is free from contamination before beginning disassembly.

6. Disconnect harness assembly (4) from flow control valve (3).

7. Make temporary marks on flow control valve (3) and the fuel injection pump for installation purpose.

8. Remove allen heads screws (2) from flow control valve (3).

9. Remove flow control valve (3) from fuel injection pump (1).

10. Use Tooling (A) to plug fuel injection pump (1).

11. Remove O-ring seal (5) and O-ring seal (6).

Flow control valve guide pins

12. Use Tooling (A) to cap flow control valve (3).

Installation Procedure 1. Ensure that all component at free from wear and damage. If any part of the flow control valve is worn or damaged, the flow control valve must be replaced as an assembly.

2. Remove cap from flow control valve (3). Position new O-ring seal (5) and new O-ring seal (6) onto flow control valve (3).

3. Install guide pins into Position (X) on fuel injection pump (1).

This document is printed from SPI². Not for RESALE

10

UENR0682

Disassembly and Assembly Section 4. Lubricate O-ring seal (5) and O-ring seal (6) with clean fuel.

Note: Ensure that the O-ring seal is not damaged or misaligned.

5. Remove plug from fuel injection pump (1). Align flow control valve (3) onto guide pins.

6. Install flow control valve (3) to fuel injection pump (1).

i05495450

Fuel Filter Base - Remove and Install Removal Procedure Table 4 Required Tools

7. Remove guide pins from the fuel injection pump.

Tool

Part Number

8. Install allen head screws (2) from the flow control valve repair kit.

A

T410437

9. Tighten allen head screws (2) equally until the flow control valve is seated correctly onto the fuel injection pump.

Note: Ensure that the allen screws are tightened equally. Failure to ensure that the allen screws are tightened equally will result in damage to the fuel injection pump.

10. Tighten allen head screws (2) to a torque of 9 N·m (80 lb in).

11. Connect harness assembly (4) to flow control valve (3).

12. Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, “Fuel System Primary (Water Separator) Element Replace” for the correct procedure.

13. Replace the filters for secondary fuel system.

Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for the correct procedure.

Part Description Capping Kit

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

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.

14. Turn the fuel supply to the ON position.

Dispose of all fluids according to local regulations and mandates.

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

1. Turn the fuel supply to the OFF position.

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

End By: a. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure.

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

3. Drain the secondary filters. Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for the correct procedure.

b. After replacement of the flow control valve, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, “Fuel Rail Pressure Problem” for the correct procedure.

This document is printed from SPI². Not for RESALE

UENR0682

11 Disassembly and Assembly Section 12. Remove bolts (2) from fuel filter base (1). Remove the fuel filter base from the mounting bracket.

Note: Note the position of different length bolts.

Illustration 8

g03390360

4. Make temporary identification marks on all the tube assemblies in order to show the correct position of the tube assemblies.On some engines the tube assemblies on the fuel filter assembly may be in a different location.

5. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

6. Remove banjo bolt (6) and remove sealing washers (5) (not shown).

7. Use Tooling (A) in order to plug tube assembly (11).

Use Tooling (A) in order to cap the port of connection (4).

8. Remove banjo bolt (8) and remove sealing washers (7) (not shown).

9. Use Tooling (A) in order to plug tube assembly (12). Use Tooling (A) in order to cap the port in fuel filter base (1).

10. If necessary, remove connection (4) from fuel filter base (1). Remove O-ring seal (3) (not shown).

11. Remove secondary filters (9) from canisters (10).

Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for the correct procedure.

Illustration 9

g03390403

13. If necessary, follow Step 13.a. through Step 13.b. in order to remove fuel filter bracket (13). a. Remove bolts (15) from fuel filter bracket (13). b. Remove fuel filter bracket (13) from inlet manifold (14).

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

This document is printed from SPI². Not for RESALE

12

UENR0682

Disassembly and Assembly Section

Illustration 10

g03390403

Illustration 11

g03390360

1. Ensure that fuel filter bracket (13) is clean and free from damage. If necessary, replace the complete fuel filter bracket.

3. Position fuel filter base (1) onto the fuel filter bracket. Install bolts (2). Tighten the bolts to a torque of 44 N·m (32 lb ft).

2. If necessary, follow Step 2.a. through Step 2.c. in order to install fuel filter bracket (13).

4. If necessary, install new fuel filters (9) to canisters (10). Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for the correct procedure.

a. Position fuel filter bracket (13) onto inlet manifold (14). b. Install bolts (15) to fuel filter bracket (13).

5. If necessary, follow Step 5.a. through Step 5.c. to install connection (4) to fuel filter base (1).

c. Tighten bolts (15) to a torque of 22 N·m (195 lb in).

a. Install a new O-ring seal (3) (not shown) to connection (4). b. Install connection (4) to fuel filter base (1). c. Tighten connection (4) to a torque of 21 N·m (186 lb in).

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

6. Install a new sealing washer (7) (not shown) onto banjo bolt (8).

This document is printed from SPI². Not for RESALE

UENR0682

13 Disassembly and Assembly Section

7. Remove plug from tube assembly (12) and install banjo bolt (8). Install remaining sealing washer (7) (not shown) onto banjo bolt (8).

8. Install banjo bolt (8) to fuel filter base (1).

9. Tighten banjo bolt (8) to a torque of 21 N·m (186 lb in).

10. Install a new sealing washer (5) (not shown) onto banjo bolt (6).

11. Remove plug from tube assembly (1211) and install banjo bolt (8). Install remaining sealing washer (5) (not shown) onto banjo bolt (6).

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

12. Install banjo bolt (6) to connection (4).

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

13. Tighten banjo bolt (6) to a torque of 21 N·m (186 lb in).

2. Turn the fuel supply to the OFF position.

14. Use Tooling (A) in order to . Use Tooling (A) in order to cap the ports in fuel filter base (1).

15. Remove the plugs from the tube assemblies.

Remove the caps from the ports in the fuel filter base.

16. Turn the fuel supply to the ON position.

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

End By: a. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05495573

Water Separator and Fuel Filter (Primary) - Remove and Install Illustration 12

Removal Procedure

3. The water separator and fuel filter can be installed in any location on a machine. Ref to the Original Equipment Manufacture (OEM) for the correct location.

Table 5 Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

g03411000

Qty 1

4. Make temporary identification marks on tube assemblies in order to show the correct position of the tube assemblies.

5. Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.

6. Disconnect tube assembly (3) and tube assembly (4) from the assembly of primary fuel filter (5).

This document is printed from SPI². Not for RESALE

14

UENR0682

Disassembly and Assembly Section 7. Use Tooling (A) in order to plug the tube assemblies. Use Tooling (A) in order to cap the connection on the primary fuel filter.

8. Disconnect the OEM harness assembly from the connection on harness assembly (7) for water in fuel sensor (6).

9. Disconnect the OEM harness assembly from the connection on harness assembly (1).

10. Remove bolts (2) and remove the assembly of primary fuel filter (5) from the mounting. Support the primary fuel filter as the bolts are removed.

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that the fuel filter base is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.

Illustration 13

g03411001

11. If necessary, follow Step 11.a. through Step 11.d. in order to disassembly the assembly of primary fuel filter (5). a. Remove connection (9) and remove O-ring seal (8). b. Remove connection (11) and remove O-ring seal (10). c. Remove water in fuel sensor (6) and remove O-ring seal (13) (not shown). d. Remove the filter element from fuel filter canister (12). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element - Replace” for the correct procedure.

Illustration 14

g03411001

2. If necessary, follow Step 2.a. through Step 2.d. in order to assembly primary fuel filter (5). a. Install a new O-ring seal (8) to connection (9).

Install connection (9) to primary fuel filter (5).

Tighten the connection to a torque of 20 N·m (177 lb in). b. Install a new O-ring seal (10) to connection (11). Install connection (11) to primary fuel filter (3). Tighten the connection to a torque of 20 N·m (177 lb in).

This document is printed from SPI². Not for RESALE

UENR0682

15 Disassembly and Assembly Section 6. Connect tube assembly (3) to primary fuel filter (5).

c. Install a new O-ring seal (13) (not shown) to water in fuel sensor (6). Install water in fuel sensor (6). Tighten water in fuel sensor (6) hand tight. d. Install a new filter element to fuel filter canister (12). Refer to Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element - Replace” for the correct procedure.

7. Remove plug from tube assembly (4). Remove cap from the connection on the primary fuel filter.

8. Connect tube assembly (4) to primary fuel filter (5).

9. Connect the OEM harness assembly to the connection on harness assembly (7) for water in fuel sensor (6).

10. Connect the OEM harness assembly to the connection on harness assembly (1).

11. Turn the fuel supply to the ON position.

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

End By: a. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05495469

Fuel Manifold (Rail) - Remove and Install Removal Procedure Table 6 Illustration 15

g03411000

3. Position the assembly of primary fuel filter (3) onto the mounting.

4. Install bolts (2) to the assembly of primary fuel filter (3).

For M8 8.8 graded bolts, tighten the bolts to a torque of 22 N·m (195 lb in).

Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

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

For M10 8.8 graded bolts, tighten the bolts to a torque of 44 N·m (32 lb ft).

For bolts that are graded differently, refer to the OEM for the correct torque values.

NOTICE Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

5. Remove plug from tube assembly (3). Remove cap from the connection on the primary fuel filter.

This document is printed from SPI². Not for RESALE

16

UENR0682

Disassembly and Assembly Section

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

8. If necessary, remove fuel pressure relief valve (6).

Refer to Disassembly and Assembly, “Relief Valve (Fuel) - Remove and Install” for the correct procedure.

Installation Procedure NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage.

Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure relief valve are installed.

Illustration 16

g03383683

1. Thoroughly clean the area around fuel manifold (2).

2. Disconnect harness assembly (4) from fuel pressure sensor (3).

3. Remove banjo bolt (1) from tube assembly (5).

4. Remove sealing washers (7) (not shown).

5. Immediately use Tooling (A) to cap the open port in fuel manifold (2). Immediately use Tooling (A) to plug the open end of tube assembly (5).

6. Remove bolt (8) from fuel manifold (2). Remove the fuel manifold from inlet manifold (9)

Illustration 17

7. If necessary, remove fuel pressure sensor (3).

Refer to Disassembly and Assembly, “Fuel Pressure Sensor - Remove and Install” for the correct procedure.

2. If necessary, install fuel pressure sensor (3). Refer to Disassembly and Assembly, “Fuel Pressure Sensor - Remove and Install” for the correct procedure.

g03383683

This document is printed from SPI². Not for RESALE

UENR0682

17 Disassembly and Assembly Section

3. If necessary, install fuel pressure relief valve (6).

Refer to Disassembly and Assembly, “Relief Valve (Fuel) - Remove and Install” for the correct procedure.

4. Position fuel manifold (2) onto inlet manifold (8).

Install bolts (7) to fuel manifold (2) finger tight.

5. Install a new set of seals and a new set of fuel injection lines. Refer to Disassembly and Assembly, “Fuel Injection Lines - Install” for the correct procedure.

6. Tighten bolts (7) to a torque of 22 N·m (195 lb in).

7. Connect harness assembly (4) to fuel pressure sensor (3).

8. Install a new sealing washer (6) (not shown) on to banjo bolt (1).

9. Remove the cap from tube assembly (5).

10. Install banjo bolt (1) to tube assembly (5). Install remaining new sealing washer (6) (not shown) to the banjo bolt.

11. Install banjo bolt (1) and tube assembly (5) to fuel manifold (2). Tighten the banjo bolt finger tight.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. When the fuel pressure relief valve is removed, a new fuel pressure relief valve must be installed.

12. Tighten banjo bolt (1) to a torque of 21 N·m (186 lb in). Ensure that tube assembly (5) is not strand as the banjo bolt is tightened.

13. Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, “Fuel System Primary (Water Separator) Element Replace” for the correct procedure.

14. Replace the filters for secondary fuel system.

Refer to Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for the correct procedure.

15. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for more information. i05495555

Relief Valve (Fuel) - Remove and Install

Illustration 18

g03377176

2. Disconnect the hose assembly from inlet connection (1).

Removal Procedure

3. Thoroughly clean the area around fuel manifold (2) and fuel pressure relief valve (1).

Table 7 Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

4. Remove bolts (4) from inlet connection (1).

Qty 1

This document is printed from SPI². Not for RESALE

18

UENR0682

Disassembly and Assembly Section 5. Remove inlet connection (1) and gasket (3) (not shown) from the inlet manifold.

6. Follow Step 6.a. through Step 6.d. in order to remove fuel pressure relief valve (5) from fuel manifold (2). a. Ensure that the area around the fuel pressure relief valve (5) and fuel manifold (2) is still thoroughly clean. b. Remove fuel pressure relief valve (5) from fuel manifold (2). c. Immediately use tooling (A) to cap the open port in fuel manifold (2). d. Immediately use Tooling (A) to cap the fuel pressure relief valve (5).

Installation Procedure Table 8

Illustration 19

g03442338

Required Tools Tool

Part Number

B

-

Part Description Bosch Grease Ft1v27

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Follow Step 1.a. through Step 1.h. in order to install a new fuel pressure relief valve (5) to fuel manifold (2). a. Remove the cap from the port in fuel manifold (2). b. Immediately clean the threads in fuel manifold (2) for fuel pressure relief valve (5). Ensure that the thread is clean and free from debris.

Ensure that the thread in the fuel manifold (2) is free from damage. c. Immediately use Tooling (A) to cap the open port in fuel manifold (2) after cleaning and inspection. d. Remove the cap from the threaded end of fuel pressure relief valve (1). Lightly lubricate the thread and bite edge (6) of the pressure relief valve with Tooling (B). e. Inspect the O-ring seal on the new fuel pressure relief valve (5) for damage. Replace the fuel pressure relief valve as an assembly if the O-ring seal is damaged. f. Remove the cap from the port of fuel manifold (2). Install fuel pressure relief valve (1) into fuel manifold (2) hand tight. g. Tighten fuel pressure relief valve (1) to a torque of 100 N·m (74 lb ft). h. Clean excessive Tooling (B) from fuel pressure relief valve (1) and fuel manifold (2).

This document is printed from SPI². Not for RESALE

UENR0682

19 Disassembly and Assembly Section

2. Clean the gasket surfaces of the inlet connection (1) and the inlet manifold.

3. Position a new gasket (3) (not shown) onto inlet connection (1).

4. Position inlet connection (1) onto the inlet manifold.

5. Install bolts (4) to inlet connection (1). Tighten the bolts to a torque of 22 N·m (195 lb in).

6. Connect the hose assembly to inlet connection (1).

Securely tighten hose clamp.

7. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime” for the correct procedure. i05495452

Fuel Injection Lines - Remove Removal Procedure for One Fuel Injection Line

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.

1. This removal procedure is for removal of one fuel injection line between the fuel manifold and the electronic unit injector.

2. Turn the fuel supply to the OFF position.

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

4. Remove the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, “Crankcase Breather - Remove” for the correct procedure.

Table 9 Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Illustration 20

g03442884

5. Remove the clamp and isolator (4) from fuel injection line (1).

6. Remove fuel injection line (1) from fuel manifold (5) and electronic unit injectors (3) (not shown).

Discard the fuel injection lines.

7. Use Tooling (A) to cap fuel manifold (5).

8. Remove seal (2) from the cylinder head.

9. Use Tooling (A) to cap electronic unit injectors (3) (not shown).

This document is printed from SPI². Not for RESALE

20

UENR0682

Disassembly and Assembly Section

Removal Procedure for Set of Fuel Injection Lines Table 10 Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

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.

1. This removal procedure is for removal of all fuel injection line between the fuel manifold, the electronic unit injectors, and fuel injection pump.

2. Turn the fuel supply to the OFF position.

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

4. Remove the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, “Crankcase Breather - Remove” for the correct procedure.

This document is printed from SPI². Not for RESALE

UENR0682

21 Disassembly and Assembly Section

Illustration 21

g03442888

5. Remove bolt (10) (not shown) and bolt (11) from the clamps for fuel injection lines.

14. Use Tooling (A) to cap fuel manifold (15) and the electronic unit injectors.

Note: On some engines there may be only one clamp retaining the fuel injection lines to the cylinder head.

15. Remove seals (7) from the cylinder head.

6. Remove the nut and bolt (13) from the clamp for fuel injection pipes.

Removal Procedure for more than One Fuel Injection Line Table 11

7. Remove the clamps and isolator (9) and the clamps and isolator (12) from fuel injection line (1) and fuel injection line (2).

8. Remove the clamps and isolator (14) from fuel injection line (1) and fuel injection line (2).

9. Remove fuel injection line (1) and fuel injection line (2) from fuel injection pump (8) and fuel manifold (15).

Discard the fuel injection lines.

10. Use Tooling (A) to cap fuel injection pump (8) and fuel manifold (15).

Required Tools Tool

Part Number

A

T410437

Part Description Capping Kit

Qty 1

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

11. Remove plastic clamp (4) and plastic clamp (6) from the assembly of fuel injection lines (3) and the assembly of fuel injection lines (5).

12. Remove fuel injection lines (3) from fuel manifold (15) and the electronic unit injectors.

Discard the fuel injection lines.

13. Remove fuel injection lines (5) from fuel manifold (15) and the electronic unit injectors.

Discard the fuel injection lines.

This document is printed from SPI². Not for RESALE

22

UENR0682

Disassembly and Assembly Section

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

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.

1. This removal procedure is for removal of more than one fuel injection line between the fuel manifold and the electronic unit injector.

2. Turn the fuel supply to the OFF position.

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

4. Remove the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, “Crankcase Breather - Remove” for the correct procedure.

Illustration 22

g03388840

5. Remove the clamp and isolator (5) from fuel injection line (1), fuel injection line (2), and fuel injection line (6).

6. Remove fuel injection line (1), fuel injection line (2), and fuel injection line (6) from fuel manifold (7) and electronic unit injectors (4) (not shown).

Discard all the fuel injection lines.

7. Use Tooling (A) to cap fuel manifold (7).

8. Remove seals (3) from the cylinder head.

9. Use Tooling (A) to cap electronic unit injectors (4) (not shown). i05495451

Fuel Injection Lines - Install Installation Procedure for One Fuel Injection Line Table 12 Required Tools Tool

Part Number

B

27610294

Part Description Injector Pipe Nut Tool

Qty 1

This document is printed from SPI². Not for RESALE

UENR0682

23 Disassembly and Assembly Section

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. This installation procedure is for installing one fuel injection line between the fuel manifold and the electronic unit injector.

Note: Ensure that the isolators are correctly positioned onto the fuel injection lines.

7. Use Tooling (B) to tighten the nuts on fuel injection line (1) to a torque of 30 N·m (266 lb in).

Note: Ensure that fuel injection lines do not contact any other engine component.

8. Install the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, “Crankcase Breather - Install” for the correct procedure.

9. Turn the fuel supply to the ON position.

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

Installation Procedure for Set of Fuel Injection Lines Table 13 Required Tools Tool

Part Number

B

27610294

Part Description Injector Pipe Nut Tool

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Illustration 23

g03444839

2. Remove the cap from electronic unit injector (3) (not shown).

3. Install a new seal (2) to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.

4. Remove the cap from fuel manifold (5).

5. Install a new fuel injection line (1) to fuel manifold (5) and electronic unit injectors (3) (not shown) hand tight. Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.

6. Install the isolator and clamp(4) onto the fuel injection lines.

1. This installation procedure is for installing all fuel injection line between the fuel manifold, the electronic unit injectors, and the fuel injection pump. Loosening of all the electronic unit injectors and the fuel manifold will be necessary. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove” and Disassembly and Assembly, “Fuel Manifold (Rail) Remove and Install” and for correct procedure.

This document is printed from SPI². Not for RESALE

24

UENR0682

Disassembly and Assembly Section

Illustration 24

g03444858

1. Install new seals (7) to the electronic unit injector and the cylinder head. Ensure that the flange on the seals is flush with the cylinder head.

9. Remove the caps from the port of the electronic unit injector and from the ports in fuel manifold (16).

2. Remove the caps from new fuel injection line (1) and new fuel injection line (2).

10. Loosely connect the nuts at both ends of fuel injection line (3) and fuel injection lines (5) to the electronic unit injector and to the appropriate port in fuel manifold (15). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.

3. Remove the caps from the appropriate ports fuel manifold (15) and fuel injection pump (8).

4. Position fuel injection line (1) and fuel injection line (2) onto fuel injection pump (8) and fuel manifold (15). Hand tighten the nuts for the fuel injection line onto the fuel manifold and the fuel injection pump.

5. Ensure that the ends of fuel injection line (1) and fuel injection line (2) are correctly seated in the fuel manifold and the fuel injection pump.

6. Position the clamps and isolator (9) and the clamps and isolator (12) to the fuel injection lines. Install new bolt (10) (not shown) and new bolt (11) hand tight. Ensure that the isolators are correctly positioned onto the fuel injection lines.

Note: On some engines there may be only one clamp retaining the fuel injection lines to the cylinder head.

7. Position the clamps and isolator (14) to the fuel injection lines. Install the nut and bolt (13) hand tight.

Note: Ensure that the isolators are correctly positioned onto the fuel injection lines.

8. Remove the caps from new fuel injection lines (3) and new fuel injection lines (5).

11. Install plastic clamp (4) and plastic clamp (6) to the assembly of fuel injection pipe (3) and the assembly of fuel injection pipe (5). Ensure that the plastic clamps are correctly seated onto the fuel injection lines.

12. Tighten the electronic unit injector and the fuel manifold. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install” and Disassembly and Assembly, “Fuel Manifold (Rail) - Remove and Install” for the correct procedure.

13. Use Tooling (B) to tighten the nuts on fuel injection line (1) and fuel injection line (2) to a torque of 30 N·m (266 lb in).

Note: Ensure that fuel injection lines do not contact any other engine component.

14. Use Tooling (B) to tighten the nuts on the assembly fuel injection line (3) and the assembly fuel injection line (5) to a torque of 30 N·m (266 lb in).

Note: Ensure that fuel injection lines do not contact any other engine component.

This document is printed from SPI². Not for RESALE

UENR0682

25 Disassembly and Assembly Section

15. Tighten the nuts and bolt (13) to a torque of 4 N·m (35 lb in).

16. Tighten bolt (10) (not shown) and bolt (11) to a torque of 4 N·m (35 lb in).

17. Install the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, “Crankcase Breather - Install” for the correct procedure.

18. Turn the fuel supply to the ON position.

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

Installation Procedure for more than One Fuel Injection Line Table 14 Required Tools Tool

Part Number

B

27610294

Part Description Injector Pipe Nut Tool

Qty 1

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. This installation procedure is for installation of more than one fuel injection line between the fuel manifold and the electronic unit injector.

Loosening of the appropriate electronic unit injectors will be necessary. Refer to Disassembly and Assembly, “Electronic Unit Injector - Remove”

Illustration 25

g03444856

2. Remove the caps from electronic unit injectors (4) (not shown).

3. Install new seals (3) to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.

4. Remove the caps from fuel manifold (7).

5. Install new fuel injection line (1), fuel injection line (2), and fuel injection line (6) to fuel manifold (7) and electronic unit injectors (4) (not shown) hand tight. Ensure that the ends of the fuel injection lines are correctly seated in the electronic unit injectors and in the fuel manifold.

6. Install the isolator and clamp(5) onto the fuel injection lines.

Note: Ensure that the isolators are correctly positioned onto the fuel injection lines.

7. Tighten the electronic unit injector. Refer to Disassembly and Assembly, “Electronic Unit Injector - Install” for the correct procedure.

8. Use Tooling (B) to tighten the nuts on fuel injection line (1), fuel injection line (2), and fuel injection line (6) to a torque of 30 N·m (266 lb in).

Note: Ensure that fuel injection lines do not contact any other engine component.

9. Install the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, “Crankcase Breather - Install” for the correct procedure.

10. Turn the fuel supply to the ON position.

This document is printed from SPI². Not for RESALE

26

UENR0682

Disassembly and Assembly Section 11. Turn the battery disconnect switch to the ON position. i05495455

Fuel Injection Pump - Remove Removal Procedure Table 15 Required Tools Part Description

Qty

Tool

Part Number

A(1)

T400011

Crankshaft Turning Tool

1

27610291

Housing

1

27610289

Engine Turning Tool

1

27610286

Timing Pin (Crankshaft)

1

27610286

Adapter

1

T410437

Capping Kit

1

A(2)

B C (1) (2)

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

1. Turn the fuel supply to the OFF position.

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

The Crankshaft Turning Tool is used on the front pulley.

This Tool is used in the aperture for the electric starting motor.

Start By: a. If necessary, remove the fuel filter base. Refer to Disassembly and Assembly, “Fuel Filter Base Remove and Install” for the correct procedure . b. If necessary, remove the fuel priming pump. Refer to Disassembly and Assembly, “Fuel Priming Pump - Remove” for the correct procedure. c. If necessary, remove the crankcase breather (Filtered Breather). Refer to Disassembly and Assembly, “Crankcase Breather (Filtered Breather) - Remove” for the correct procedure.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

Illustration 26

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

g03388236

3. Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.

4. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install” for the correct procedure.

5. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke.

6. Install Tooling (C) through Hole (W) in order to lock the crankshaft.

This document is printed from SPI². Not for RESALE

UENR0682

27 Disassembly and Assembly Section

Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.

Illustration 28

g03388256

12. Place a suitable container below fuel injection pump (9) in order to catch any fuel that might be spilled.

13. Clean fuel injection pump (9) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.

Illustration 27

g03385397

7. For an engine that is not supplied with cover (3) on front cover (5). Remove the front cover. Refer to Disassembly and Assembly, “Front Cover Remove and Install” for the correct procedure.

14. Disconnect the tube assembly from connection (21) from fuel injection pump (9). Use Tooling (D) in order to plug the tube assembly. Cap the connection in the fuel injection pump.

8. Use a suitable tool to remove cover (3) from front cover (5).

15. Remove fuel injection lines (10) from the fuel injection pump and the fuel manifold. Refer to Disassembly and Assembly, “Fuel Injection Lines Remove” for the correct procedure.

9. Remove O-ring seal (4) (not shown) from cover (3).

Note: Discard the fuel injection lines.

10. Loosen nut (8).

16. Remove banjo bolt (11) from tube assembly (13).

Remove sealing washers (12) (not shown). Use Tooling (D) in order to plug the tube assembly. Cap the ports in the fuel injection pump.

11. Remove nut (8) and spring washer (7) (not shown).

17. Remove banjo bolt (15) from tube assembly (16).

Remove sealing washers (17) (not shown). Use Tooling (D) in order to plug the tube assembly. Cap the ports in the fuel injection pump.

18. Remove banjo bolt (18) from tube assembly (20).

Remove sealing washers (19) (not shown). Use Tooling (D) in order to plug the tube assembly. Cap the ports in the fuel injection pump.

This document is printed from SPI². Not for RESALE

28

UENR0682

Disassembly and Assembly Section 19. Remove banjo bolt (22) and banjo bolt (25) from tube assembly (24). Remove sealing washers (23) (not shown) and sealing washers (26) (not shown).

Use Tooling (D) in order to plug the tube assembly.

Cap the ports in the fuel injection pump.

20. Disconnect harness assembly (14) from the flow control valve on fuel injection pump (9).

Note: The harness assembly should be positioned in order to avoid an obstruction to the fuel injection pump.

Illustration 30

g03388316

26. If necessary, follow Step 26.a. through Step 26.b. in order to remove the bracket from the fuel injection pump. a. Position fuel injection pump (9) in a suitable stand. b. Remove bolts (33) and remove bracket (34).

Illustration 29

g03388285

27. If necessary, remove flow control valve (32). Refer to Disassembly and Assembly, “Flow Control Valve - Remove and Install” for the correct procedure.

21. Remove the nut and bolt (29) from bracket (30).

22. Remove bolts (31) and remove bracket (30) from the cylinder block.

23. Remove bolts (28) from fuel injection pump (9).

Support the fuel injection as the bolts are removed.

24. Remove fuel injection pump (9) from housing front (26).

i05495453

Fuel Injection Pump - Install Installation Procedure Table 16

Required Tools

25. Remove O-ring seal (27) (not shown).

Part Description

Qty

Tool

Part Number

A(1)

T400011

Crankshaft Turning Tool

1

27610291

Housing

1

27610289

Engine Turning Tool

1

27610286

Timing Pin (Crankshaft)

1

27610287

Adapter

1

A(2)

B (1) (2)

The Crankshaft Turning Tool is used on the front pulley.

This Tool is used in the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

This document is printed from SPI². Not for RESALE

UENR0682

29 Disassembly and Assembly Section

NOTICE Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.

2. If necessary, install flow control valve (32). Refer to Disassembly and Assembly, “Flow Control Valve Remove and Install” for the correct procedure.

Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, “General Hazard Information and High Pressure Fuel Lines” for safety information.

Refer to System Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTICE Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.

Illustration 31

Illustration 32

g03388285

Illustration 33

g03388369

g03388316

1. If necessary, follow Step 1.a. through Step 1.d. in order to install the bracket to the fuel injection pump. a. Position fuel injection pump (9) in a suitable stand.

The Angle (Y) should be 43 degrees. The Angle (Z) should be 18 degrees

b. Position bracket (34) onto fuel injection pump (9). Ensure that the bracket is correctly orientated. c. Install bolts (33) hand tight. d. Tighten bolts (33) to a torque of 22 N·m (195 lb in).

This document is printed from SPI². Not for RESALE

Thank you very much for your reading.

Please Click Here Then Get More Information.