Disassembly and

Assembly

2506-15 Industrial Engine

M G A (Engine)

MGB (Engine)

M G D (Engine)

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Installation Procedure

Note: The crankshaft front seal and the wear sleeve

must be replaced as a unit.  Once the crankshaft

front seal and the wear sleeve are separated, these

components can not be used again.

Table 28

Required Tools

Part

Tool

B

Number

GE50008

GE50009

GE50014

GE50013

Part Description

Qty

1

Seal Locator

C

Bolt

3

D

Nut (Seal Installer)

Seal Installer

1

E

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Note: The crankshaft  front seal and the wear

sleeve must be replaced at the  same time. Once

the crankshaft front seal and the wear  sleeve are

separated, these components cannot be used again.

Note: Do not lubricate the crankshaft seal or the wear

g01044861

sleeve. The crankshaft seal must be installed dry.

Illustration 70

Typical example

1.  Before installation of the crankshaft front seal

and the wear sleeve, inspect the crankshaft for

scratches. Also, inspect the crankshaft for any

distortion on the surface that may lead to an out of

round condition. Use a polishing cloth in order to

remove any imperfections on the crankshaft.

1.  Use a 4 mm (0.158 inch) drill in order to make

three or more holes in wear sleeve (2).

2.  Use Tooling (A) to remove the wear sleeve.

3.  Use a 4 mm (0.158 inch) drill in order to make

2.  Clean the outside diameter of the crankshaft.

three or more holes in crankshaft front seal (1).

4.  Use Tooling (A) to remove crankshaft front seal

(1).

This document has been printed from SPI². Not for Resale

40

KENR6232

Disassembly and  Assembly Section

i02554751

Front Cover - Remove

Removal Procedure

Start By:

a.  Remove the fan drive. Refer to Disassembly and

Assembly, “Fan drive - Remove”.

b. Remove the  assembly of the vibration damper

and the crankshaft pulley. Refer to Disassembly

and Assembly, “Vibration Damper and Pulley -

Remove and Install”.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

g01056093

Illustration 71

Typical example

3.  Fasten Tooling (B) to the crankshaft with Tooling

(C).

Dispose of all fluids according to local regulations and

mandates.

Note: Install the crankshaft front seal with the arrow

that shows the direction of crankshaft rotation toward

the front of the engine.

NOTICE

Keep all parts clean from contaminants.

4.  Position wear sleeve (2) and crankshaft front seal

(1) on Tooling (B). Install Tooling (E) on Tooling

(B). Lubricate the face of the washer on Tooling

(D). Install Tooling (D) on Tooling (B).

Contaminants may cause  rapid wear and  shortened

component life.

5.  Tighten Tooling (D) until Tooling (E) contacts

Tooling (B).

6.  Remove Tooling (D) and Tooling (E) from Tooling

(B).

7.  Remove Tooling (C) and Tooling (B) from the

crankshaft.

End By:

a.  Install the vibration damper and the pulley. Refer

to Disassembly and Assembly, “Vibration Damper

and Pulley - Remove and Install”.

g01286405

Illustration 72

1.  Loosen bolts (2). Remove front cover (3) from

front housing (1).

This document has been printed from SPI². Not for Resale

KENR6232

41

Disassembly and  Assembly Section

2.  Remove bolts (2) and seal (4) from front cover (3).

i02554750

Front Cover - Install

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01286471

Illustration 74

Tightening sequence

2.  Position front cover (3) on front  housing (1).

Tighten the bolts to a torque of 20 N·m (15 lb ft)

in the numerical sequence  that is shown in

Illustration 74.

End By:

a.  Install the assembly of the vibration  damper

and the crankshaft pulley. Refer to Disassembly

and Assembly, “Vibration Damper and Pulley -

Remove and Install”.

b. Install the  fan drive. Refer to Disassembly and

Assembly, “Fan drive - Install”.

g01286405

Illustration 73

1.  Install seal (4) and bolts (2) to front cover (3).

i02554763

Gear Group (Front) - Remove

Removal Procedure

Start By:

a.  Remove the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove and

Install”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

This document has been printed from SPI². Not for Resale

42

KENR6232

Disassembly and  Assembly Section

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

Note: Be sure to mark the orientation of each of the

gears for installation purposes.

g01287363

Illustration 77

Typical example

5.  Remove bolts (11), plate (12), and idler  gear

assembly (10).

g01287358

Illustration 75

1.  Remove bolts (2) and thrust plate (1).

g01287364

Illustration 78

2.  Remove sealing plate (3) and adapter (4).

Typical example

6.  Remove bolts (14), plate (15), and cluster gear

3.  Remove O-ring seal (5) and O-ring seal (6) from

assembly (13).

sealing plate (3).

g01287359

Illustration 76

Typical example

4.  Remove bolts (8), plate (9), and adjustable idler

gear assembly (7).

This document has been printed from SPI². Not for Resale

KENR6232

43

Disassembly and  Assembly Section

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

g01287365

Illustration 79

Typical example

Note: The backlash for  the camshaft gear and

the adjustable idler gear assembly will need to be

readjusted at assembly.

7.  Remove fasteners (17) and remove stub shaft

g01287373

Illustration 80

Typical example

assembly (16).

8.  Remove fasteners (19) and remove stub shaft

1.  Install stub shaft (20). Apply Tooling (B) to bolts

(21). Install bolts (21) and tighten to a torque of

55 N·m (40 lb ft) in sequence. (1, 3, 4, 5, 2, 1, 2,

3, 4, 5, 1)

(18).

9.  Remove bolts (21) and remove stub shaft (20).

i02554762

Note: If any studs  are loose or the threads are

Gear Group (Front) - Install

damaged, install new studs to the front housing.

2.  Install stub shaft (18). Apply Tooling (A) to the

studs and the bolt for stub shaft (18). Tighten nuts

(19) and the bolt to a torque of 55 N·m (40 lb ft).

Installation Procedure

3.  Install stub shaft assembly (16). Do not tighten

nuts (17) and the bolt for the shaft assembly  at

this time. The nuts and the  bolt for stub shaft

assembly (16) will need to be tightened when the

backlash is adjusted.

Table 29

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART

A

21820117

1

Note: If shaft assembly (16) is removed, the backlash

for the camshaft gear  and the adjustable idler

gear will need to be readjusted. Refer to Systems

Operation, Testing and Adjusting,  “Gear Group

(Front) - Time”.

Threadlock and Nutlock

POWERPART

Rubber Grease

B

21820221

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

This document has been printed from SPI². Not for Resale

44

KENR6232

Disassembly and  Assembly Section

8.  Apply Tooling (A) to bolts (14). Position  plate

(15) with the oil groove toward  the gear face.

Install bolts (14) and tighten to a torque of 28 N·m

(21 lb ft).

g01287363

Illustration 83

Typical example

g01287358

Illustration 81

9.  Position idler gear (10) on the shaft assembly.

4.  Install new O-ring seals (5) and (6) to sealing plate

10. Apply Tooling (A) to bolts (11). Position plate

(12) with the oil groove toward  the gear face.

Install bolts (11) and tighten to a torque of 28 N·m

(21 lb ft).

(3). Lubricate O-ring seal (5) with Tooling (B).

5.  Install adapter (4). Ensure that the dowel in the

adapter engages the hole in the camshaft.

11. Install the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove and

Install.” for the correct procedure.

6.  Install sealing plate (3) and thrust plate (1) in the

front housing. Apply Tooling (A) to bolts (2). Install

bolts (2) and tighten the bolts to a torque of 12 N·m

(106 lb in). Ensure that sealing plate (3) and O-ring

seal (6) are seated against the cylinder head.

12. Check the backlash for the camshaft gear and

the adjustable idler gear. If necessary, adjust the

backlash. Refer to Systems Operation, Testing

and Adjusting, “Gear Group (Front) - Time”.

Note: Ensure that No. 1  piston at the top center

position on the compression stroke. Refer to Systems

Operation, Testing and Adjusting,  “Finding Top

Center Position for No. 1 Piston”.

Note: The camshaft gear must be installed and the

adjustable idler gear must be removed in order to

perform the backlash adjustment procedure.

g01287378

Illustration 82

Typical example

g01288571

Illustration 84

7.  Put cluster gear assembly (13) on the stub shaft.

Ensure that Timing Marks (V) are aligned on the

cluster gear assembly and the crankshaft gear.

13. Once the correct backlash has been obtained,

follow Steps 13.a through 13.d in order to secure

stub shaft assembly (16).

This document has been printed from SPI². Not for Resale

KENR6232

45

Disassembly and  Assembly Section

a.  Remove one nut (17).

b. Remove the crankshaft position sensor. Refer to

Disassembly and Assembly, “Crankshaft Position

Sensor - Remove and Install”.

b. Apply Tooling  (A) to the nut.

c.  Install nut (17) and tighten to  a torque of

c.  Remove the belt tightener. Refer to Disassembly

55 N·m (40 lb ft).

and Assembly, “Belt Tightener - Remove”.

d. Repeat the procedure  for the remaining nuts

d. Remove  the fuel transfer pump.  Refer to

Disassembly and Assembly, “Fuel Transfer Pump

- Remove”.

and the bolt.

Note: Removing and installing one nut at time will

ensure that the position of the stub shaft assembly

is not affected.

e.  Remove the water pump. Refer to Disassembly

and Assembly, “Water Pump - Remove”.

Note: Ensure that the timing mark on the camshaft

gear is aligned with the  timing mark on the front

housing before the adjustable idler gear assembly

is installed.

f.  Remove  the gear group (front).  Refer to

Disassembly and Assembly, “Gear Group (Front)

- Remove ”.

g. Remove  the crankshaft front seal. Refer  to

Disassembly and Assembly, “Crankshaft Front

Seal - Remove”.

h. Remove the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and

Install”.

i.   Remove the engine support. Refer to Disassembly

and Assembly, “Engine Support (Front) - Remove

and Install”.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

g01287359

Illustration 85

Typical example

14. Put adjustable idler gear assembly (7) on the

stub shaft assembly. Position plate (9) with the oil

groove toward the face of the gear. Apply Tooling

(A) to bolts (8). Install bolts (8). Tighten bolts (8)

to a torque of 28 N·m (21 lb ft).

Dispose of all fluids according to local regulations and

mandates.

End By:

NOTICE

Keep all parts clean from contaminants.

a.  Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Install”.

Contaminants may cause  rapid wear and  shortened

component life.

i02554765

Housing (Front) - Remove

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

Removal Procedure

Start By:

a.  Remove the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position

Sensor - Remove and Install”.

This document has been printed from SPI². Not for Resale

46

KENR6232

Disassembly and  Assembly Section

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

g01286831

Illustration 86

1.  Remove bolts (3) and bracket (2).

2.  Remove the brackets that support the harness

assembly.

3.  Use a suitable lifting device to support the weight

of front housing (1). The front housing  weighs

approximately 62 kg (137 lb).

g01286831

Illustration 87

1.  Thoroughly clean the mating surfaces of  the

cylinder block and front housing (1). Ensure that

the dowels in the cylinder block protrude 1.91 cm

(0.75 inch) from the mating surface.

4.  Remove bolts (4).

5.  Use the lifting device to remove front housing (1).

6.  Remove joint (5).

2.  Install a new joint (5) on the dowels in the cylinder

block.

Note: It is not necessary to remove the dowels in the

Note: Trim the joint even with the bottom of the front

cylinder block that locate the front housing.

housing after assembly.

i02554764

3.  Use a suitable lifting device to align front housing

(1) with the dowels in the cylinder block. The front

housing weighs approximately 62 kg (137 lb).

Housing (Front) - Install

4.  Install front housing (1) to the cylinder  block.

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

50 N·m (37 lb ft).

Installation Procedure

5.  Position bracket (2) and install bolts (3). Ensure

that the bracket  that supports the harness

assembly is secured by the  appropriate bolt.

Tighten the bolts to a torque of 47 N·m (35 lb ft).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

6.  Install the remaining bracket that supports the

harness assembly.

This document has been printed from SPI². Not for Resale

KENR6232

47

Disassembly and  Assembly Section

End By:

a.  Install the engine support. Refer to Disassembly

and Assembly, “Engine Support (Front) - Remove

and Install”.

b. Install the  engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and

Install”.

c.  Install the crankshaft front  seal. Refer to

Disassembly and Assembly, “Crankshaft Front

Seal - Install”.

d. Install the gear group (front). Refer to Disassembly

g01286833

and Assembly, “Gear Group (Front) - Install ”.

Illustration 88

1.  Loosen clamp (2) and remove hose (3)  from

connection (1) on the valve mechanism cover.

Remove the hose.

e.  Install the water pump. Refer to Disassembly and

Assembly, “Water Pump - Install”.

f.  Install the fuel transfer pump. Refer to Disassembly

Installation Procedure

and Assembly, “Fuel Transfer Pump - Install”.

g. Install the belt tightener. Refer to Disassembly and

NOTICE

Assembly, “Belt Tightener - Install”.

Keep all parts clean from contaminants.

h. Install the  crankshaft position sensor. Refer to

Disassembly and Assembly, “Crankshaft Position

Sensor - Remove and Install”.

Contaminants may cause  rapid wear and  shortened

component life.

i.   Install the camshaft position sensor. Refer to

Disassembly and Assembly, “Camshaft Position

Sensor - Remove and Install”.

i02554701

Crankcase Breather - Remove

and Install

(Open Breather)

Removal Procedure

g01286833

Illustration 89

1.  Ensure that hose (3) is  clean and free from

NOTICE

damage.

Keep all parts clean from contaminants.

2.  Install hose (3) to connection (1) on the  valve

Contaminants may cause  rapid wear and  shortened

component life.

mechanism cover. Tighten clamp (2).

This document has been printed from SPI². Not for Resale

48

KENR6232

Disassembly and  Assembly Section

i02554786

Valve Mechanism Cover  -

Remove and Install

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01283967

Illustration 91

Tightening sequence for the valve mechanism cover

3.  Gradually loosen isolated bolts (1) in reverse

numerical order. Refer to Illustration 91. This will

help prevent distortion of the valve mechanism

cover.

4.  Remove the valve mechanism cover (2). Remove

isolated bolts (1) and joint  (4) from the valve

mechanism cover.

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01283965

Illustration 90

1.  Loosen clip (5) and remove breather hose (6) from

valve mechanism cover (2).

2.  Disconnect the harness assembly from connector

(3). Remove the bolts and the washers that secure

the connector to valve mechanism cover (2).

g01283965

Illustration 92

1.  Install isolated bolts (1) and a new joint (4) to valve

mechanism cover (2).

This document has been printed from SPI². Not for Resale

KENR6232

49

Disassembly and  Assembly Section

g01283967

Illustration 93

Tightening sequence for the valve mechanism cover

2.  Install valve mechanism cover (2). Gradually

tighten the isolated bolts (1) to a torque of 20 N·m

(15 lb ft) in the numerical sequence that is shown

in Illustration 93.

g01047470

Illustration 94

3.  Position connector (3) into valve mechanism cover

(2). Install the bolts and the washers that secure

the connector to the valve mechanism  cover.

Torque the bolts to a torque of 1.5 N·m (13 lb in).

Connect the harness assembly to the connector.

Valve rocker  arms and unit  injector rocker  arms

can move  on the shaft after  the bolts have  been

removed. The shaft should be kept level when re-

moved from the cylinder head.  To avoid possible

personal  injury, keep  fingers  clear of  the  valve

rocker  arms  and  the  unit injector  rocker  arms

when lifting the assembly from the cylinder head.

4.  Install clip (5) and breather hose (6)  to valve

mechanism cover (2).

i02554783

Rocker Arm  and Shaft -

Remove

1.  Remove bolts (2).

2.  Use Tooling (A) to remove rocker  arm shaft

assembly (4), valve rocker arms (3), and electronic

unit injector rocker arms (1) as a unit.

Removal Procedure

3.  Make a temporary mark on the valve bridges in

order to show the location and the orientation.

Remove the valve bridges from the cylinder head.

Table 30

Required Tools

Part

Note: Identification will ensure that the valve bridges

can be reinstalled in the original location  and the

original orientation. Do not interchange the location

or the orientation of used valve bridges.

Tool

Number

Part Description

Qty

A

27610322

Lifting Bracket

1

Start By:

i02554781

Rocker Arm - Disassemble

a.  Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and Install”.

Disassembly Procedure

NOTICE

Keep all parts clean from contaminants.

Start By:

Contaminants may cause  rapid wear and  shortened

component life.

a.  Remove the rocker arms and the rocker shaft.

Refer to Disassembly and Assembly, “Rocker Arm

and Shaft - Remove”.

This document has been printed from SPI². Not for Resale

50

KENR6232

Disassembly and  Assembly Section

i02554780

NOTICE

Rocker Arm - Assemble

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Assembly Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01047557

Illustration 95

1.  Remove valve rocker arms (11) and electronic unit

injector rocker arm (3) from rocker shaft assembly

(4).

2.  Remove nut (7) from adjustment screw (8).

g01047557

Illustration 96

3.  Remove adjustment screw (8) from valve rocker

arms (11).

Note: Do not reuse the O-ring seal on the adjustment

screw if the button is removed from the adjustment

screw.

4.  Remove button (10) from adjustment screw (8).

Remove O-ring seal (9) from  the adjustment

screw.

1.  Install a new O-ring seal (9) in button (10).

5.  Remove nut (2) from unit injector adjustment

2.  Use a soft hammer  to seat button (10) on

screw (1).

adjustment screw (8).

6.  Remove unit injector adjustment screw (1) from

3.  Install adjustment screw (8) in valve rocker arms

electronic unit injector rocker arm (3).

(11). Install nut (7) on the adjustment screw.

7.  Remove button (6) from unit injector adjustment

screw (1). Remove O-ring seal (5) from the unit

injector adjustment screw.

4.  Install a new O-ring seal (5) in button (6).

5.  Use a soft hammer to seat button  (6) on unit

injector adjustment screw (1).

6.  Install unit injector adjustment screw  (1) in

electronic unit injector rocker arm (3). Install nut

(2) on the unit injector adjustment screw.

7.  Lubricate rocker shaft assembly (4) with clean

engine oil.

8.  Install valve rocker arms (11) and electronic unit

injector rocker arm (3) on rocker shaft assembly

(4).

This document has been printed from SPI². Not for Resale

KENR6232

51

Disassembly and  Assembly Section

End By:

3.  Install bolts (2) and tighten to a torque of 109 N·m

(80 lb ft).

a.  Install the rocker arms and the rocker shaft. Refer

to Disassembly and Assembly, “Rocker Arm and

Shaft - Install”.

4.  Adjust the valve lash for the inlet valves and the

exhaust valves. Refer to Systems  Operation,

Testing and Adjusting,  “Engine Valve Lash

- Inspect/Adjust”. Adjust the  electronic unit

injectors. Refer to Systems Operation, Testing and

Adjusting, “Electronic Unit Injector - Adjust”.

i02554782

Rocker Arm and Shaft - Install

End By:

a.  Install the valve mechanism cover.  Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and Install”.

Installation Procedure

Table 31

Required Tools

i02554713

Tool

Part Number

Part Description

Lifting Bracket

Qty

Cylinder Head - Remove

A

27610322

1

NOTICE

Removal Procedure

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Table 32

Required Tools

Tool

A

Part Number

GE50020

Part Description

Qty

1

1.  Install the valve bridges.

Socket

Note: Install used valve  bridges in the original

location and in the original orientation. Ensure that the

valve bridges are correctly seated on the valves. New

valve bridges may be installed in either orientation.

B

VP12712

Lifting Bracket

1

Start By:

a.  Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.

b. Remove  the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic  Unit

Injector - Remove”.

c.  Remove the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove”.

d. Remove the water temperature regulator housing.

Refer to Disassembly and Assembly,  “Water

Temperature Regulator Housing - Remove and

Install ”.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

g01117306

Illustration 97

2.  Use Tooling (A) in order to position rocker arm

shaft assembly (4), valve rocker arms (3), and

electronic unit injector rocker arms (1) as a unit,

on the cylinder head.

Dispose of all fluids according to local regulations and

mandates.

This document has been printed from SPI². Not for Resale

52

KENR6232

Disassembly and  Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

g01067185

Illustration 99

Typical example

4.  Disconnect hose assembly (8) from the front of the

cylinder head. Remove the bolt and the clip that

secures the hose assembly to the cylinder head.

5.  Disconnect hose assembly (9) from the rear of the

cylinder head. Remove the bolt and the clip that

secures the hose assembly to the cylinder head.

6.  Remove bolt (14), the clip and the spacer. Remove

the crankcase breather from the cylinder head.

7.  Remove bolts (7) and remove the bracket from

the cylinder head.

8.  Slide the locking tab into the unlocked position

and disconnect the harness assembly from inlet

manifold pressure sensor (10).

g01287358

9.  Slide the locking tab into the unlocked position

and disconnect the harness assembly from inlet

manifold temperature sensor (13).

Illustration 98

1.  Remove bolts (2) and thrust plate (1).

2.  Remove sealing plate (3) and adapter assembly

10. Remove the bolts and the clips that secure the

(4).

harness assembly to the cylinder head.

3.  Remove O-ring seal (5) and O-ring seal (6) from

11. Remove bolts (12), the bracket and air inlet elbow

(11) from the cylinder head. Remove the O-ring

seal from the air inlet elbow.

sealing plate (3).

Note: Be sure to mark the orientation of the air inlet

elbow for installation purposes.

This document has been printed from SPI². Not for Resale

KENR6232

53

Disassembly and  Assembly Section

g01288987

Illustration 100

Typical example

12. Remove bolts (15) from the front lifting bracket.

g01288989

Illustration 102

Typical example

16. Remove cylinder head gasket (18) and O-ring

seal (19).

17. Remove seal (22) and seals (24).

18. Remove spacer plate (21).

19. Remove O-ring seal (20) from the dowel in the

cylinder block. Remove spacer plate gasket (24).

g01288988

Illustration 101

Typical example

i02554711

Cylinder Head - Install

13. Use Tooling (A) in order to remove cylinder head

bolts (16).

14. Attach Tooling (B) and a suitable lifting device

to cylinder head (17). The weight of the cylinder

head assembly is approximately 235 kg (518 lb).

Ensure that all of the following items  are clear

from the cylinder head: harness assemblies, tube

assemblies, and hose assemblies.

Installation Procedure

Table 33

Required Tools

Part

15. Use the lifting device to carefully remove cylinder

Tool

A

Number

GE50020

VP12712

-

Part Description

Qty

1

head (17).

Socket

B

Lifting Bracket

Guide Stud

1

C

2

POWERPART

D

E

F

CV60895

21820221

2182638

1

1

1

Special Lubricant

POWERPART

Rubber Grease

POWERPART

Retaining Compound

This document has been printed from SPI². Not for Resale

54

KENR6232

Disassembly and  Assembly Section

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01288718

Illustration 104

Typical example

6.  Install Tooling (C) to the cylinder block in  the

positions that are shown in Illustration 104.

g01288989

Illustration 103

Typical example

Note: Thoroughly clean the spacer plate and  the

bottom surface of the cylinder head and the top of

the cylinder block. A new spacer plate gasket and

a cylinder head gasket must be installed when the

cylinder head is removed.

g01288988

Illustration 105

Typical example

1.  Install O-ring seal (20) on the dowel in the cylinder

7.  Attach Tooling (A) and a suitable lifting device to

cylinder head (17). The weight of cylinder head

assembly (17) is approximately 235 kg (518 lb).

block.

Note: Ensure that  the dowel protrudes from

the face of the  cylinder block by 20 ±  0.5 mm

(0.79 ± 0.02 inch).

8.  Use the lifting device to align cylinder head (17)

with Tooling (C). Carefully install the cylinder head

onto the dowel pins in the cylinder block.

2.  Install spacer plate gasket (23) on the cylinder

block.

9.  Remove Tooling (A).

3.  Install spacer plate (21).

10. Apply Tooling (D) to the threads of cylinder head

bolts (16) and both sides of the washers. Install

cylinder head bolts (16).

4.  Install seals (24) and seal (22).

5.  Install cylinder head gasket (18) on the spacer

plate. Install O-ring seal (19) on the dowel in the

cylinder block.

g01072801

Illustration 106

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KENR6232

55

Disassembly and  Assembly Section

Note: The bolts that are Marked “X”  are 216 mm

(8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24, and

26. The rest of the bolts are 194 mm (7.6 inch) long.

15. Connect hose assembly (8) to the cylinder head.

Install the bolt and the clip that secures the hose

assembly to the cylinder head.

11. Tighten the cylinder head bolts according to the

16. Install bolt (14), the clip and the  spacer that

secures the breather tube to the cylinder head.

Tighten bolt (14) to a torque of 10 N·m (89 lb in).

following procedure.

a.  In the numerical sequence, tighten Bolts 1

through 26 to a torque of 270 N·m (200 lb ft).

17. Position the bracket on the cylinder head and

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

47 N·m (35 lb ft).

b. In  the numerical sequence, tighten Bolts 1

through 26 to a torque of 450 N·m (330 lb ft).

18. Connect the harness assembly to inlet manifold

pressure sensor (10). Slide the locking tab into

the locked position.

c.  In the numerical sequence, again tighten Bolts

1 through 26 to a torque of 450 N·m (330 lb ft).

19. Connect the harness assembly to inlet manifold

temperature sensor (13). Slide the locking tab into

the locked position.

20. Install the bolts and the clips that secure  the

harness assembly to the cylinder head.

g01288987

Illustration 107

12. Install bolts (15) to the front lifting bracket. Tighten

the bolts to a torque of 105 N·m (77 lb ft).

g01287358

Illustration 109

21. Install O-ring seal (5) and O-ring seal  (6) on

sealing plate (3). Lubricate O-ring seal (5) with

Tooling (E).

g01067185

Illustration 108

Typical example

22. Install adapter assembly (4) and sealing plate (3).

Ensure that the dowel in adapter assembly (4)

engages the hole in the camshaft.

13. Install a new O-ring seal to air inlet elbow (11).

Position the bracket and air inlet elbow (11) on the

cylinder head. Install bolts (12) and tighten to a

torque of 47 N·m (35 lb ft).

Note: Ensure that the O-ring seal stays in the groove

in sealing plate (3).

23. Install thrust plate (1). Apply Tooling (F) to bolts

(2). Hold the thrust plate in position  and install

bolts (2). Evenly tighten bolts (2) to a torque of

12 N·m (106 lb in).

Note: Ensure that the air inlet elbow is installed in the

correct orientation.

14. Connect hose assembly (9) to the cylinder head.

Install the bolt and the clip that secures the hose

assembly to the cylinder head.

This document has been printed from SPI². Not for Resale

56

KENR6232

Disassembly and  Assembly Section

Note: Ensure that the O-ring seal stays in the groove

in sealing plate (3).

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

End By:

a.  Install the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Install”.

b. Install  the electronic unit injectors. Refer  to

Disassembly and Assembly, “Electronic Unit

Injector - Install”.

c.  Install the water temperature regulator housing.

Refer to Disassembly and Assembly,  “Water

Temperature Regulator Housing - Remove and

Install”.

d. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.

i02554691

Camshaft - Remove

Removal Procedure

Table 34

g01287358

Illustration 110

Required Tools

1.  Remove bolts (2) and thrust plate (1).

Tool

A

Part Number

GE50018

GE50017

GE50015

GE50025

Part Description

Qty

1

Cradle

2.  Remove sealing plate (3) from the front housing.

Remove adapter assembly (4) from the camshaft.

B

Guide

1

C

Camshaft Pilot

Camshaft Hook

2

3.  Remove O-ring seal (5) and O-ring seal (6) from

sealing plate (3).

D

2

NOTICE

Start By:

Care must  be used when  removing or  installing the

camshaft. Do not damage the finshed surfaces of the

camshaft or the camshaft bearings.

a.  Remove the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove and

Install”.

b. Remove the  rocker arms and the rocker shafts.

Refer to Disassembly and Assembly, “Rocker Arm

and Shaft - Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01286820

Illustration 111

Typical example

This document has been printed from SPI². Not for Resale

KENR6232

57

Disassembly and  Assembly Section

4.  Use the bolts for the rocker arm shaft assembly to

install Tooling (A) at Location (Y).

g01047996

Illustration 115

Typical example

g01047945

Illustration 112

Typical example

7.  Move camshaft (8) forward and install one Tooling

(C) to the end of the camshaft. Again, move the

camshaft forward and install remaining Tooling (C)

to the back of first Tooling (C). Align camshaft (8)

with the bore of Tooling (B). Tighten the bolts that

hold Tooling (B) to front housing (7).

5.  Install Tooling (B) on front housing (7). Tooling (B)

is used to support camshaft (8). Do not tighten the

bolts for Tooling (B) at this time.

Note: Tooling (C) will support the rear of the camshaft

as the camshaft is moved out of the cylinder head

and into Tooling (B).

8.  Use Tooling (D) to move camshaft (8) toward the

front of the engine. Reposition Tooling  (D), as

required.

Note: Avoid lifting the camshaft with Tooling (D). The

camshaft should rest on Tooling (A). Lifting  of the

camshaft can cause misalignment as the camshaft

is removed, resulting in damage  to the camshaft

bearings.

g01056675

Illustration 113

Typical example

9.  Carefully slide the camshaft to the front of the

engine for removal. Use two people to remove

the camshaft. Keep the camshaft level while the

camshaft is being removed from  the cylinder

head. The weight of camshaft (8) is approximately

39 kg (86 lb).

6.  Remove Torx screws (9) and cover (10). Remove

the O-ring seal from the cover.

Note: Rotate the camshaft during removal. This will

prevent the camshaft from binding in the camshaft

bearings.

10. Remove Tooling (C) from the camshaft.

11. Remove Tooling (B) from front housing (7).

12. Remove Tooling (A) from the cylinder head.

g01287879

Illustration 114

This document has been printed from SPI². Not for Resale

58

KENR6232

Disassembly and  Assembly Section

i02554692

Camshaft - Install

Installation Procedure

Table 35

Required Tools

Tool

A

Part Number

GE50018

GE50017

GE50015

GE50025

GE50016

Part Description

Qty

1

Cradle

B

Guide

1

g01286820

Illustration 116

C

Camshaft Pilot

Camshaft Hook

Alignment Sleeve

2

2.  Install Tooling (A) on the cylinder head at Location

D

2

(Y).

H

1

POWERPART

Rubber Grease

J

21820221

1

POWERPART

Thread Lock and  Nut

Lock

K

21820117

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01056901

NOTICE

Illustration 117

Typical example

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

3.  Install Tooling (B) on front housing (7). Do not

tighten the bolts that hold  Tooling (B) to front

housing (7) at this time.

4.  Use Tooling (H) to align Tooling  (B) with the

camshaft bearings. Tighten the bolts that hold

Tooling (B) to front housing (7). Remove Tooling

(H).

NOTICE

Care must  be used when  removing or installing  the

camshaft. Do not damage the finshed surfaces of the

camshaft or the camshaft bearings.

Note: Tooling (H) should move freely from the bore

of Tooling (B).

1.  Ensure that the camshaft and camshaft bearings

are thoroughly clean. Lubricate the  camshaft

bearings with clean engine oil.

This document has been printed from SPI². Not for Resale

KENR6232

59

Disassembly and  Assembly Section

g01293986

Illustration 118

Typical example

5.  Install both Tooling (C) to the rear of camshaft (8).

6.  Use two people to install the  camshaft. Use

Tooling (D) to assist in  aligning camshaft (8)

with the camshaft bearings. Carefully slide the

camshaft into the cylinder head from the front of

the engine. Keep the camshaft level while  the

camshaft is being installed in the cylinder head.

The weight of camshaft (8) is approximately 39 kg

(86 lb).

g01287358

Illustration 120

11. Install O-ring seals (5) and (6) in sealing plate (3).

Lubricate O-ring seal (5) with a Tooling (J).

12. Install adapter assembly (4) and sealing plate (3).

Ensure that the dowel in adapter assembly (4)

engages the hole in the camshaft.

Note: Rotate the camshaft during installation. This

will prevent the camshaft from binding in the camshaft

bearings.

Note: Ensure that the O-ring seal stays in the groove

in sealing plate (3).

7.  Remove Tooling (C) when camshaft (8) is fully

13. Install thrust plate (1). Apply Tooling (K) to bolts

(2). Hold the thrust plate in position  and install

bolts (2). Evenly tighten bolts (2) to a torque of

12 N·m (106 lb in).

installed in the bore.

8.  Remove Tooling (A) from the cylinder head.

9.  Remove Tooling (B) from the front housing.

Note: Ensure that the O-ring seal stays in the groove

in sealing plate (3).

14. Lubricate the camshaft lobes with clean engine

oil.

End By:

a.  Install the camshaft gear. Refer to Disassembly

and Assembly, “Camshaft Gear - Remove and

Install”.

b. Install  the rocker arms and the rocker shafts.

Refer to Disassembly and Assembly, “Rocker

Arms and Shaft - Install”.

g01056675

Illustration 119

10. Install a new O-ring seal on cover (10). Position

the cover on the rear of the cylinder head. Install

torx screws (9) and tighten to a torque of 6 N·m

(53 lb in).

This document has been printed from SPI². Not for Resale

60

KENR6232

Disassembly and  Assembly Section

i02554695

Camshaft Gear - Remove and

1.  Position the No. 1 piston at the top center of the

compression stroke. Refer to Systems Operation,

Testing and Adjusting,  “Finding Top Center

Position for No. 1 Piston”.

Install

2.  Verify that the timing mark on camshaft gear (1) is

aligned with Timing Mark (X) on front housing (3).

Removal Procedure

Table 36

Required Tools

Tool

Part Number

Part Description

Guide Stud

Qty

A

GE50019

1

Start By:

a.  Remove the front cover. Refer to Disassembly and

Assembly, “Front Cover - Remove”.

NOTICE

g01286832

Illustration 122

Keep all parts clean from contaminants.

3.  Remove one bolt (2). Install Tooling (A).

Contaminants may cause  rapid wear and  shortened

component life.

4.  Remove the remaining bolts (2) and remove

camshaft gear (1).

NOTICE

Installation Procedure

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

Table 37

Required Tools

Tool

Part Number

Part Description

Guide Stud

Qty

A

GE50019

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Do not turn the  crankshaft or the camshaft while  the

camshaft gear is  removed. If the front  gear group is

not correctly timed during installation, interference can

occur between the pistons and the valves, resulting in

damage to the engine.

g01286828

Illustration 121

This document has been printed from SPI². Not for Resale

KENR6232

61

Disassembly and  Assembly Section

g01286832

g00593987

Illustration 123

Illustration 125

Torque sequence for the camshaft gear

1.  Align the hole in the back of camshaft gear (1) with

the dowel in the adapter. Position camshaft gear

(1) onto Tooling (A) and install the camshaft gear.

4.  Tighten the bolts for the  camshaft gear in a

numeric sequence 1, 4, 2, 5, 3, 6, 1, 4 to a torque

of 240 N·m (180 lb ft).

5.  Check the backlash between the camshaft gear

and the adjustable idler gear. The backlash should

be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer

to Systems Operation, Testing and Adjusting,

“Gear Group (Front) - Time”  for the backlash

adjustment procedure.

End By:

a.  Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Install”.

i02554694

Camshaft Bearings - Remove

Removal Procedure

g01286828

Illustration 124

Table 38

Note: Camshaft timing is critical. The timing mark on

the camshaft gear must be aligned with the timing

mark on the front cover when the No. 1 piston is at

the top center of the compression stroke. Refer to

Systems Operation,Testing and Adjusting, “Gear

Group (Front) - Time”.

Required Tools

Part

Tool

Number

27610271

27610312

27610313

27610314

Part Description

Qty

1

Camshaft Bearing Tool

Group

A

2.  Verify that the timing mark on camshaft gear (1) is

Camshaft Bearing Pilot

1

aligned with Timing Mark (X) on front housing (3).

B

Taperlock Stud

1

1/2 - 13 by 1 9/16 inch

Note: If the timing marks are not aligned,  remove

camshaft gear (1) and rotate the camshaft until the

timing marks are aligned.

C

Puller Plate

1

Start By:

3.  Install bolts (2) finger tight. Remove Tooling (A)

and install the remaining bolt (2).

a.  Remove the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Remove”.

This document has been printed from SPI². Not for Resale

62

KENR6232

Disassembly and  Assembly Section

i02554693

Camshaft Bearings - Install

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Installation Procedure

Table 39

Required Tools

Part

Tool

Number

27610271

27610312

27610313

Part Description

Qty

1

Camshaft Bearing Tool

Group

A

Camshaft Bearing Pilot

1

B

Taperlock Stud

1

1/2 - 13 by 1 9/16 inch

C

D

27610314

27610315

27610316

Puller Plate

1

1

1

g01159745

Alignment Bushing

Backup Plate

Illustration 126

1.  Remove the No. 7 camshaft bearing (rear). Work

from the rear of the  engine to the front of the

engine.

E

F

Bolt

27610317

27610318

1

1

1/2 - 13 by 1 inch

Spacer Plate

2.  Install the small end of Tooling (B) in camshaft

bearing (1).

NOTICE

Keep all parts clean from contaminants.

3.  Position Tooling (C) over Tooling  (A). Install

Tooling (A) through the cylinder head on Tooling

(B).

Contaminants may cause  rapid wear and  shortened

component life.

Note: Tooling (C) is installed on the outside of the

cylinder head. Tooling (C) is required  in order to

remove all the camshaft bearings from the cylinder

head.

4.  Use Tooling (A) to remove camshaft bearing (1)

from the cylinder head.

5.  Remove Tooling (B) from Tooling (A) and remove

the camshaft bearing.

g01159754

Illustration 127

1.  Install the No. 7 camshaft bearing  (rear), as

follows:

a.  Insert the large end of Tooling (B) into the No.

7 camshaft bore.

b. Position Tooling  (C) over Tooling (A). Install

Tooling (A) through the  cylinder head on

Tooling (B).

This document has been printed from SPI². Not for Resale

KENR6232

63

Disassembly and  Assembly Section

c.  Position camshaft bearing (1) on Tooling (B).

Install Tooling (E) on Tooling (B).

Note: Refer to Specifications, “Cylinder Head” for

appropriate information for the orientation  of the

camshaft bearings in the cylinder head.

d. Use  Tooling (A) in order to pull  camshaft

bearing (1) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts the

face of the camshaft bore, the camshaft bearing is

properly installed.

g01159758

Illustration 129

3.  Install the No. 1 camshaft bearing (front),  as

follows:

a.  Insert the large end of Tooling (B) into the No.

1 camshaft bore. Assemble Tooling (A) and

Tooling (D) on Tooling (B).

b. Position camshaft bearing (1)  on Tooling (B).

Install Tooling (E) and Tooling (F) on Tooling

(B).

Note: Refer to Specifications, “Cylinder Head” for

appropriate information for the location  and the

orientation of the camshaft bearings in the cylinder

head.

g01159756

Illustration 128

2.  Install the No. 6 through No. 2 camshaft bearings,

as follows:

Note: Tooling (F) is used to seat the No. 1 camshaft

a.  Insert the large end of Tooling (B)  into the

bearing to the correct depth in the camshaft bore.

camshaft bore.

c.  Use Tooling (A) in order to  pull the No. 1

camshaft bearing into the No. 1 camshaft bore.

When the chamfer of Tooling  (E) contacts

the face of the camshaft bore, the camshaft

bearing is properly installed.

Note: Use Tooling (D) to align Tooling (A) and Tooling

(B) with the camshaft bearing bores. Install Tooling

(D) in the inside diameter of any installed camshaft

bearing between Tooling (A) and Tooling (B).

b. Install  Tooling (A) on Tooling (B). Position

camshaft bearing (1) on Tooling (B).  Install

Tooling (E) on Tooling (B).

End By:

a.  Install the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Install”.

Note: Refer to Specifications, “Cylinder Head” for

appropriate information for the  location and the

orientation of the camshaft bearings in the cylinder

head.

c.  Use Tooling (A) in order to  pull camshaft

bearing (1) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts the

face of the camshaft bore, the camshaft bearing is

properly installed.

This document has been printed from SPI². Not for Resale

64

KENR6232

Disassembly and  Assembly Section

i02554730

Engine Oil Pan - Remove and

Install

Removal Procedure

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

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

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01284906

Illustration 130

Typical example

Hot oil  and hot components can  cause personal

injury. Do not allow  hot oil or hot components to

contact the skin.

2.  Remove drain plug (3). Remove washer (2) from

drain plug (3).

3.  Loosen bolts (5). Remove engine oil pan (4).

1.  Drain the engine oil into a  suitable container

for storage or disposal. Refer to Operation and

Maintenance Manual, “Engine Oil - Change”.

4.  Remove bolts (5) and seal (1) from engine oil pan

(4).

Installation Procedure

Table 40

Required Tools

Part

Tool

Number

Part Description

Qty

A

CH10888

Silicone Gasket

1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

1.  Clean the mating surfaces of the engine oil pan,

cylinder block, front housing, and the  flywheel

housing.

This document has been printed from SPI². Not for Resale

KENR6232

65

Disassembly and  Assembly Section

3.   Apply a bead of Tooling (A) to positions (X).

g01284984

Illustration 133

Tightening sequence

4.  Install engine oil pan (4). Tighten bolts (5) in the

numerical sequence that is shown in Illustration

133. Tighten the bolts  to a torque of 47 N·m

(35 lb ft).

5.  Install a new washer (2) to drain plug (3). Install

drain plug (3) to engine oil pan (4). Tighten the

drain plug to a torque of 45 N·m (33 lb ft).

g01284906

Illustration 131

Typical example

6.  Fill the engine oil pan to the correct level. Refer to

Operation and Maintenance Manual, “Engine Oil

- Change”.

2.  Install seal (1) and bolts (5) to engine oil pan (4).

i02554715

Cylinder Liner - Remove

Removal Procedure

Table 41

Required Tools

Part

Tool

Part Description

Qty

Number

A

GE50001

Cylinder Liner Puller

1

Start By:

a.  Remove the pistons and connecting rods. Refer

to Disassembly and Assembly,  “Pistons and

Connecting Rods - Remove”.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01285214

Illustration 132

Typical example

This document has been printed from SPI². Not for Resale

66

KENR6232

Disassembly and  Assembly Section

1.  Make temporary identification marks in order to

show the location of the cylinder liners.

g01111530

Illustration 135

2.  Install liner seals (3) on cylinder liner (1).

g01111472

Illustration 134

3.  Apply Tooling (C) on the cylinder block liner bore

2.  Use Tooling (A) to remove cylinder liner (1).

surfaces and liner seals (3).

3.  Remove liner seals (3) and filler band (2) from

4.  Dip filler band (2)  in clean engine oil for  a

moment. Install the filler band on the cylinder liner

immediately.

cylinder liner (1).

i02554714

Cylinder Liner - Install

5.  Use Tooling (B) to install cylinder liner (1) in the

cylinder block. Ensure that any marks in relation

to the cylinder liner projection are in alignment.

End By:

Installation Procedure

a.  Install the pistons and connecting rods. Refer

to Disassembly and Assembly,  “Pistons and

Connecting Rods - Install”.

Table 42

Required Tools

Tool

Part Number

Part Description

Qty

i02554770

Piston Cooling Jets - Remove

and Install

B

GE50000

Cylinder Liner Installer

1

POWERPART

Rubber Grease

C

21820221

1

NOTICE

Keep all parts clean from contaminants.

Removal Procedure

Contaminants may cause  rapid wear and  shortened

component life.

Table 43

Required Tools

Note: Ensure that the cylinder liners and the cylinder

Tool

Part Number

Part Description

Qty

block are clean and free from damage.

A

CH11148

Engine Turning Tool

1

1.  Check the cylinder liner projection. Refer  to

Systems Operation, Testing and  Adjusting,

“Cylinder Liner Projection - Inspect”.

Start By:

a.  Remove the engine  oil pump. Refer  to

Disassembly and Assembly, “Engine Oil Pump -

Remove”.

This document has been printed from SPI². Not for Resale

KENR6232

67

Disassembly and  Assembly Section

2.  Position piston cooling jet (2) in the cylinder block.

Install bolt (1). Tighten the  bolt to a torque of

40 N·m (30 lb ft).

NOTICE

Keep all parts clean from contaminants.

Note: Ensure that the nozzles of the piston cooling

Contaminants may cause  rapid wear and  shortened

component life.

jet are not damaged or distorted.

End By:

a.  Install the engine oil pump. Refer to Disassembly

and Assembly, “Engine Oil Pump - Install”.

i02554775

Pistons and Connecting Rods

- Remove

Removal Procedure

g01103621

Illustration 136

Table 45

1.  Use Tooling (A) to rotate the crankshaft in order to

Required Tools

gain access to the piston cooling jet.

Tool

Part Number

Part Description

Qty

2.  Remove bolt (1) and piston cooling jet (2).

A

CH11148

Engine Turning Tool

1

Installation Procedure

Start By:

Table 44

a.  Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.

Required Tools

Tool

Part Number

Part Description

Qty

b. Remove  the engine oil  pump. Refer to

Disassembly and Assembly, “Engine Oil Pump -

Remove”.

A

CH11148

Engine Turning Tool

1

NOTICE

c.  Remove the piston cooling  jets. Refer to

Disassembly and Assembly, “Piston Cooling Jets

- Remove and Install”.

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01103621

Illustration 137

1.  Use Tooling (A) to rotate the crankshaft in order to

gain access to the piston cooling jet.

This document has been printed from SPI². Not for Resale

68

KENR6232

Disassembly and  Assembly Section

i02554773

Pistons and Connecting Rods

- Disassemble

Disassembly Procedure

Table 46

Required Tools

Part

Tool

A

Number

Part Description

Retaining Ring Pliers

Piston Ring Expander

Qty

1

g00998389

Illustration 138

-

-

B

1

1.  Use Tooling (A) to rotate the crankshaft until the

piston is at the bottom center.

Start By:

2.  Remove the carbon ridge from the top  inside

surface of the cylinder liner.

a.  Remove the pistons and connecting rods. Refer

to Disassembly and Assembly,  “Pistons and

Connecting Rods - Remove”.

3.  Inspect the connecting rod and connecting rod cap

for the proper identification mark. The connecting

rod and the connecting rod cap should have an

etched number on the side. The number should

match the cylinder number. Mark the connecting

rod and the connecting rod cap, if necessary.

Note: Mark the components of  each piston and

connecting rod assembly. The components must be

reinstalled in the original location. Do not interchange

components.

Note: Do not stamp the connecting rod assembly.

Stamping or punching the connecting rod assembly

could cause the connecting rod to fracture.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

4.  Remove bolts (1) and connecting rod bearing cap

(2). Push the connecting rod until the piston rings

are out of the cylinder liner.

g00998390

Illustration 139

5.  Remove piston (3) and the connecting rod from

the cylinder liner.

Note: Be careful not to damage the  cylinder liner

or the crankshaft journal during the removal of the

piston and the connecting rod.

g01017728

Illustration 140

This document has been printed from SPI². Not for Resale