Perkins 2000, 2200, 2300, 2500, 2800, Eagle Series Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Perkins 2000, 2200, 2300, 2500, 2800, Eagle Series Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Perkins 2000, 2200, 2300, 2500, 2800, Eagle Series Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KENR6224 - Troubleshooting (2506-15 Industrial Engine).pdf
KENR6230 - Specifications (2506-15 Industrial Engine).pdf
KENR6231 - Systems Operation_Testing & Adjusting (2506-15 Industrial Engine).pdf
KENR6232 - Disassembly & Assembly (2506-15 Industrial Engine).pdf
KENR6233 - Schematic (2506-15 Industrial Engine Electrical System).pdf
KENR6905 - Specifications (2206-E13 Industrial Engine).pdf
KENR6906 - Disassembly & Assembly (2206-E13 Industrial Engine).pdf
KENR6907 - Systems Operation_Testing & Adjusting (2206-E13 Industrial Engine).pdf
KENR6908 - Troubleshooting (2206-E13 Industrial Engine).pdf
KENR6909 - Schematic (2206-13 Industrial Engine Electrical System).pdf
Perkins 2300, 2500, 2800 Series Diesel Engine Training.pdf
SEBU8313 - Operation & Maintenance Manual (2506-15 Industrial Engine).pdf
SEBU8337 - Operation & Maintenance Manual (2206-E13 Industrial Engine).pdf
TPD1516E1 - User’s Handbook (2800 Series_Model 2806C-E18 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TPD1517E1 - Workshop Manual (2800 Series_Models 2806C-E18 TAG1 TAG2 & TAG3 (6 cylinder turbocharged diesel engines for industrial, applications)).pdf
TSD3215E12 - User’s Handbook (All 2000 diesel models (Six cylinder diesel engines for industrial applications)).pdf
TSD3244E - User’s Handbook (Eagle TX & Eagle 800).pdf
TSD3245E2 - Workshop Manual (2000 Series_6 cylinder diesel engines for industrial applications).pdf
TSD3409E4 - User’s Handbook (2000 Series_Models 2006SI & 2006TSI_6 cylinder spark ignited engines for industrial applications).pdf
TSD3429E3 - User’s Handbook (Eagle TX2000).pdf
TSD3433E1 - Workshop Manual (Eagle TX & Eagle 800 & Eagle 2000_6 cylinder diesel engines for Trucks).pdf
TSD3449E2 - User’s Handbook (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3450E - Workshop Manual (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3453E3 - Diagnostic Manual (2800 Series_Models 2806C-E16 & 2806C-E18 (6 cylinder turbocharged diesel engine)).pdf
TSD3454E2 - User's Handbook (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3455E1 - Workshop Manual (2300 Series_Model 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3455E2 - Workshop Manual (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3457E2 - Diagnostic Manual (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engine)).pdf
TSL4247 - Diagnostic Manual (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engine)).pdf
PRODUCT DETAILS:
Total Pages: 2,601 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR6224 - Troubleshooting (2506-15 Industrial Engine)...3
KENR6230 - Specifications (2506-15 Industrial Engine)...147
KENR6231 - Systems Operation_Testing & Adjusting (2506-15 Industrial Engine)...183
KENR6232 - Disassembly & Assembly (2506-15 Industrial Engine)...243
KENR6233 - Schematic (2506-15 Industrial Engine Electrical System)...343
KENR6905 - Specifications (2206-E13 Industrial Engine)...345
KENR6906 - Disassembly & Assembly (2206-E13 Industrial Engine)...381
KENR6907 - Systems Operation_Testing & Adjusting (2206-E13 Industrial Engine)...501
KENR6908 - Troubleshooting (2206-E13 Industrial Engine)...557
KENR6909 - Schematic (2206-13 Industrial Engine Electrical System)...701
Perkins 2300, 2500, 2800 Series Diesel Engine Training...703
SEBU8313 - Operation & Maintenance Manual (2506-15 Industrial Engine)...853
SEBU8337 - Operation & Maintenance Manual (2206-E13 Industrial Engine)...933
TPD1516E1 - User’s Handbook (2800 Series_Model 2806C-E18 (6 cylinder turbocharged diesel engines for industrial applications))...1021
TPD1517E1 - Workshop Manual (2800 Series_Models 2806C-E18 TAG1 TAG2 & TAG3 (6 cylinder turbocharged diesel engines for industrial, applications))...1083
TSD3215E12 - User’s Handbook (All 2000 diesel models (Six cylinder diesel engines for industrial applications))...1275
Perkins 2000 Series...1275
All 2000 diesel models...1275
USER’s HANDBOOK...1275
Six cylinder diesel engines for industrial applications...1275
This publication is divided into six chapters:...1276
1 General information...1276
2 Engine views...1276
3 Operation instructions...1276
4 Preventive maintenance...1276
5 Engine fluids...1276
6 Fault diagnosis...1276
Publication TSD 3215E, Issue 12...1275
© Proprietary information of Perkins Engines Company Limited, all rights reserved...1275
The information is correct at the time of print...1275
Published in May 1999 by Technical Publications...1275
Perkins Engines Company Limited, Lancaster Road,...1275
Shrewsbury, Shropshire, SY1 3NX, England...1275
Contents...1277
1 General information...1277
2 Engine views...1277
3 Operation instructions...1277
4 Preventive maintenance...1278
5 Engine fluids...1279
6 Fault diagnosis...1279
General information...1281
Introduction...1281
Safety precautions...1282
How to care for your engine...1283
Engine preservation...1284
1 Remove the thermostat from its housing and carefully clean it. Apply a silicone grease, such as...1284
2 Operate the engine until the normal temperature of operation is reached. Stop the engine and dr...1284
3 Fill the canisters of the oil filter with PX4 corrosion inhibitor and fit the canisters to the ...1284
4 Fill the sump, to the normal oil level, with PX4 corrosion inhibitor and, once again, run the e...1284
5 Stop the engine, disconnect the fuel supply pipe and connect the pipe to a supply of PX4 corros...1284
6 Disconnect the supply of PX4 corrosion inhibitor from the fuel system and seal the end of the p...1284
7 Remove the fuel injectors and put them in a container of PX4 corrosion inhibitor...1284
8 Set the fuel control lever to the NO FUEL position, remove the rocker covers and disconnect the...1285
9 Turn the engine by the use of the starter and, at the same time, spray PX4 corrosion inhibitor ...1285
10 Spray 40 cc of PX4 corrosion inhibitor into each cylinder, through the openings for the fuel i...1285
11 Spray PX4 corrosion inhibitor around the valves and around the rocker assemblies. Fit the rock...1285
12 Drain the PX4 corrosion inhibitor from the sump of the engine and from the oil filter canister...1285
13 Drain the cooling system and fill with the recommended coolant mixture (see "Coolant" on page ...1285
14 Wait for 15 minutes, then drain completely the coolant mixture. Fit a NO COOLANT label to the ...1285
15 Disconnect the exhaust pipe at the turbocharger outlet, or at the junction of the manifolds if...1285
16 Inject two grammes of VPI 260 powder into the turbocharger, if relevant...1285
17 Disconnect the air ducts between the air filter(s) and the turbocharger and inject two grammes...1285
18 Inject two grammes of VPI 260 powder into each paper element type air filter. Other types of a...1285
19 Spray Crodafluid PM47 onto areas of the engine and auxiliary equipment which are not protected...1285
20 Cover, completely, the alternator and the starter motor in mouldable wax wrapping, and seal wi...1285
21 Seal the air filter inlets, the crankcase breather and all other openings with mouldable wax w...1285
22 Remove all drive belts, apply French chalk to the belts and put them in a sealed plastic bag. ...1285
23 Fasten to the engine a label which indicates:...1285
Approved products for engine preservation...1286
Component...1286
Product...1286
Manufacturer...1286
Parts and Service...1287
Engine identification...1288
Engine data...1289
(1) Important for the protection of the turbocharger bearings...1290
Engine views...1291
Introduction...1291
Location of engine parts...1291
1 Thermostat housing...1291
2 Alternator...1291
3 Belt tensioner...1291
4 Canisters of the lubricating oil filter...1291
5 Oil cooler...1291
6 Breather pipe...1291
7 Starter motor...1291
8 Air charge cooler/inlet manifold...1291
9 Rocker cover...1291
1 Coolant pipe...1292
2 Fuel filter canister...1292
3 Turbocharger...1292
4 Dipstick and tube...1292
5 Filler cap for the engine lubricating oil...1292
6 Fuel lift pump...1292
7 Relief valve for the fuel...1292
8 Exhaust manifold...1292
9 Fuel injector...1292
Operation instructions...1293
How to prepare a new or an overhauled engine...1293
1 Check that all protection covers and blanking plugs have been removed...1293
2 Fit all components which were removed for storage or for transport...1293
3 Ensure that the drain plugs for the coolant and for the lubricating oil are securely fitted...1293
4 Where necessary, connect the remote control linkages, the pressure gauge pipes, the air inlet p...1293
5 Connect the fuel pipes...1293
6 Connect the exhaust pipes...1293
7 Fill the fuel tank/s with the correct grade of fuel (see "Diesel fuel" on page 53)...1293
8 Fill the cooling system with the approved coolant mixture (see "Coolant mixture" on page 53)...1293
9 Fill the sump to the ‘H’ mark on the dipstick with the correct grade of lubricating oil (see "L...1293
10 Remove the plug from the right side of the fuel injection pump and fill the fuel injection pum...1293
11 Add oil to the turbocharger, or to the two turbochargers if relevant, as follows: Clean the ar...1293
12 Eliminate air from the fuel system (see page 41)...1293
13 Lubricate all of the control linkages and check the linkages for free movement...1293
14 Ensure that the stop control is in the STOP position and that the lever of the speed control i...1293
Normal start procedures...1294
1 Check that the level of the coolant is just at the bottom of the filler extension in the radiat...1294
2 Check the engine oil level. With the engine stopped the oil level must be at the ‘H’ mark on th...1294
3 Check the level in the fuel tank. Open the fuel valve, if one is fitted...1294
How to start the engine...1295
1 Move the speed control lever to the maximum speed position...1295
2 Press the start switch and release it when the engine starts...1295
3 Move the speed control lever to the idle position...1295
1 ‘ER’ system. Remove the cap (A1) of the capsule chamber and pull the plunger (A2) fully out. In...1295
2 After a short delay, when the capsule is empty, repeat the operation with two or three more cap...1295
3 ‘Viso-F’ system. Use the canister to fill the reservoir to the MAX mark. Then operate the pump ...1295
4 Move the lever for the speed control away from the IDLE position and operate the start switch. ...1295
5 When the engine starts and runs, release the start switch and continue to operate the pump unti...1295
1 Move the lever for the speed control away from the IDLE position and operate the start switch...1296
2 When the engine turns, pull the control knob to operate the priming valve for two seconds and t...1296
3 According to the adverse ambient temperature, repeat the operation of the priming valve until t...1296
4 Do not turn the engine continuously at cranking speed for more than 20 seconds. If the engine d...1296
How to run the engine...1296
1 Do not operate the engine at high speeds and loads until the coolant has reached a minimum temp...1296
2 Do not allow the engine to run at idle speed, or without load, for prolonged periods...1296
3 Do not exceed the maximum rated speed of the engine...1296
4 Never allow an engine to continue to run if the oil pressure is below 207 kN/m2 (30 lbf/in2) at...1296
5 Fill the fuel tank/s at the end of each day to prevent condensation and to allow sediment to fa...1296
How to stop the engine...1296
1 Operate the engine for 3 minutes at idle speed with no load to allow the turbocharger to reduce...1296
2 Move the switches for the engine protection devices to their OFF positions...1296
3 Move the stop control or switch to the STOP position and release it after the engine has stopped...1296
Running-in after a repair...1297
1 Run the engine without a load until the normal temperature is reached...1297
2 During a period of three to four hours, increase gradually the load on the engine until the fin...1297
Preventive maintenance...1299
Preventive maintenance periods...1299
Schedule for engines in normal use...1300
A...1300
B...1300
C...1300
D...1300
E...1300
Operation...1300
(1) By a person who has had the correct training...1300
Schedule for engines in intermittent use...1301
A...1301
B...1301
C...1301
Operation...1301
(1) By a person who has had the correct training...1301
How to check the coolant level...1302
How to check the lubricating oil level...1302
Air filter...1303
1 Loosen the clamp ring and remove the assembly of the dust bowl and the baffle plate...1303
2 Remove the wing nut and separate the dust bowl and the baffle plate...1303
3 Remove the debris from the dust bowl; clean and assemble the two components...1303
4 Remove the wing nut which retains the filter element and withdraw carefully the filter element...1303
5 Use compressed air at a maximum pressure of 700 kN/m2 (100 lbf/in2) to clean the inner side of ...1303
6 Put a light inside the element and inspect the material of the element for damage. Thin areas o...1303
7 Clean the body of the air filter, fit the element and the assembly of the dust bowl and the baf...1303
8 Press the reset button (B1) on the restriction indicator...1303
How to check the drive belts...1304
How to adjust the tension of the fan belts...1305
How to adjust the tension of the alternator belt...1306
How to renew the engine lubricating oil...1307
1 Operate the engine until it is warm...1307
2 Stop the engine, remove the sump drain plug (A1, B1, C1, C2 or D1) and drain the lubricating oi...1307
3 Fit the drain plug and a new sealing washer and, according to the type of thread, proceed as fo...1307
4 Renew both of the oil filter canisters, see "How to renew the canisters of the oil filter" on p...1308
5 Clean the area around the oil filler cap and remove the cap. Fill the sump to the H mark on the...1308
6 Operate the engine and check for leakage from the filter canisters. When the engine has cooled,...1308
How to renew the canisters of the oil filter...1309
1 Put a tray under the canisters and use a strap wrench, 21825 825, to remove each canister...1309
2 Check that the sealing rings (A1) are correctly fitted to the new canisters and clean the conta...1309
3 Fill the two new canisters with new engine lubricating oil of the correct grade and lubricate t...1309
4 To install the new canisters use this procedure: Tighten the canisters, on their adaptors, unti...1309
How to renew the rotor of the by-pass filter for the lubricating oil...1310
1 Clean the area around the by-pass filter. Remove the filter bowl (A2), remove and discard the r...1310
2 Remove the seal (A4) from the filter bowl and clean all the components, especially the recess f...1310
3 Fit a new seal to the recess in the filter bowl and lubricate the face of the seal with clean e...1310
4 Fit a new rotor to the spindle and ensure that it can rotate freely. Fit the filter bowl and ti...1310
5 When the engine is operated, check for leakage from the by-pass filter...1310
How to renew the canister of the main fuel filter...1311
1 Clean the area around the filter and remove the fuel filter canister. If necessary, use a strap...1311
2 Check that the sealing ring (A1) is fitted correctly to the new canister and clean the contact ...1311
3 Fill the new canister with clean fuel oil of the correct specification, lubricate the top of th...1311
4 To install the new canister use this procedure: Tighten the canister on its adaptor, until the ...1311
How to drain and clean the primary fuel filter...1312
1 Remove the drain plug (A5) from the base of the filter bowl and allow all water and sediment to...1312
2 Fit the drain plug and tighten it securely...1312
1 Remove the three bolts and remove the sediment bowl...1312
2 Clean all of the components with paraffin and dry them with compressed air...1312
3 Fit the sediment bowl to the filter head, together with a new sealing ring (A3). Align the clam...1312
How to check the specific gravity of the coolant...1313
1 Put a hydrometer, and a reliable thermometer, into the antifreeze mixture and check the reading...1313
2 Compare the readings obtained with the chart and adjust the strength of the mixture as necessary...1313
1 Open the cover of the refractometer, check that the clear panel is clean and use a small syring...1313
2 Spread the coolant over the full area of the clear panel and close the cover. Hold the refracto...1313
3 Compare the reading with the chart in the instructions; adjust the strength of the mixture as n...1313
Antifreeze/water...1313
(% by volume)...1313
Protection down to...1313
(C)...1313
How to check the pH value of the coolant...1314
Fuel injector fault...1315
How to remove a fuel injector...1315
1 Clean the area around the fuel injector...1315
2 Disconnect and remove the leak-off pipe from the fuel injector...1315
3 Disconnect and remove the high pressure pipe. If necessary, release the pipe clip. Do not bend ...1315
4 Remove the bolts and the clamp which retains the fuel injector and withdraw the fuel injector. ...1315
5 To remove a tight fuel injector, use the slide hammer, 21825 849 (A1) and the relevant adaptor ...1315
Fuel injector sleeves...1316
How to correct a fuel injector sleeve...1316
1 To retain carbon and metal particles, grease must be applied to both of the cutters of the tool...1316
2 When a fuel injector is removed, if the copper sealing washer remains in the fuel injector slee...1316
How to fit a fuel injector...1317
1 Ensure that the fuel injector sleeve is clean and is free from carbon deposits...1317
2 Fit a new rubber seal (A1) onto the body of the fuel injector and a new copper sealing washer (...1317
3 Apply evenly anti-seize compound (‘Morris K72’ or equivalent) to the body of the fuel injector ...1317
4 Fit the fuel injector into the fuel injector sleeve. Apply an even layer of anti-seize compound...1317
5 Fit the high-pressure fuel pipe. Ensure that there is no tension on the connections and that th...1318
6 Fit and tighten all clamps which may have been removed...1318
7 Fit the leak-off pipe, complete with new washers, and eliminate air from the fuel system, see "...1318
8 Run the engine and check for leakage...1318
How to eliminate air from the fuel system...1319
1 Ensure that there is fuel in the fuel tank and that the source of any leakage has been eliminated...1319
2 Loosen the union at the outlet pipe of the lift pump. Operate the hand priming pump (A1) to all...1319
3 Continue to operate the hand priming pump and loosen the union on the outlet side of the fuel f...1319
4 Continue to operate the hand priming pump and loosen, one at a time, each union where the high ...1320
5 When all the unions are tightened fully, continue to operate the hand priming pump until the re...1320
How to check the tappet clearances...1321
Valves set on cylinder No...1321
Check tappets on cylinder No...1321
1 Remove the rocker covers...1321
2 Turn the crankshaft in the normal direction of rotation until the inlet valve of number 6 cylin...1321
3 Check the clearances of the valves of number 1 cylinder and adjust them if it is necessary (A)...1321
4 Continue to turn the engine and adjust the remainder of the tappets in the sequence given above...1321
5 Fit the rocker covers...1321
Alternator...1322
1 Check the condition and the tension of the drive belt, and adjust or renew as necessary...1322
2 Disconnect the two wires of the regulator (B1) from the terminals on the holder (B2) of the car...1322
3 Remove the screws which retain the holder of the carbon brushes, disconnect the wires and lift ...1322
4 Check the carbon brushes for damage and ensure that they are suitable for use. The minimum poss...1322
5 Remove the four screws which retain the housing of the carbon brushes, withdraw the housing and...1322
6 Clean the components and remove all of the dirt. Use a soft clean rag which is damp with gasoli...1322
Starter motor...1323
1 Clean the outside of the starter motor and remove the commutator cover. Use dry compressed air ...1323
2 Inspect the commutator for wear and damage. A polished dark copper finish indicates that the co...1323
3 Ensure that the carbon brushes slide freely in their holder and check that the load of the spri...1323
4 If new carbon brushes are necessary, the shape of the contact faces must conform to the radius ...1323
5 Spread a thin application of glycerine on the gasket of the cover for the carbon brushes, and f...1323
6 Remove the screws from the three points shown by arrows (A) and put three or four drops of SAE ...1323
7 Clean the splines of the pinion assembly and lubricate them with a thin application of graphite...1324
8 Ensure that the starter motor is assembled correctly to the engine and retain it securely with ...1324
9 Fit the lugs of the relevant cables to the two terminals. Ensure that the polarity of the cable...1324
10 Hold a 19 mm (0.75 in) A/F spanner on the inner lock nuts to ensure that they do not move whil...1324
How to drain the coolant system...1325
1 Ensure that the engine is level...1325
2 Remove carefully the filler cap of the radiator, especially if the engine is hot...1325
3 Remove the coolant drain plug (A1) from the rear of the left side of the engine. Ensure that th...1325
4 To drain the radiator, refer to the Manufacturer’s Instruction Publication...1325
5 Flush the system with clean water...1325
6 Fit the engine drain plug and all items which were removed in accordance with the Manufacturer’...1325
7 Fit a ‘coolant drained’ label if the coolant system is not to be filled immediately...1325
How to clean the coolant system...1326
1 Fill the system with clean water, at the same time add the necessary amount of Symperonic ‘N’ a...1326
2 Operate the engine until the coolant reaches the normal temperature of operation, then operate ...1326
3 Stop the engine and drain immediately the coolant from all of the drain outlets...1326
4 Allow the engine to cool, then fill the system with clean water. Allow a minimum of 5 litres (1...1326
5 Operate the engine as in step 2, but maintain maximum speed for 5 minutes only...1326
6 Repeat steps 3, 4 and 5...1326
7 Drain the system completely and close the drain outlets. Fill the system with the correct coola...1326
How to fill the coolant system...1326
How to check the turbocharger...1327
1 Apply air pressure up to a maximum of 207 kN/m2 (30 lbf/in2) and feel for movement of the end o...1327
2 If the rod fails to move, disconnect the rod from its lever and try to move the lever by hand. ...1327
3 With the rod still disconnected, test the assembly again with air pressure upto 207 kN/m2 (30 l...1327
How to tighten the bolts of the cylinder head...1328
1 Remove the rocker covers and the rocker assembly...1328
2 Clean the nuts and the heads of the bolts which retain the cylinder heads...1328
3 Make a temporary mark on each nut and the head of each bolt, and also on the cylinder heads. En...1328
4 Work on one nut or one bolt at a time, use the sequence shown in (A) and proceed as follows:...1328
5 Fit the rocker gear, tighten the bolts evenly and gradually to a torque of 40 Nm (30 lbf ft)...1328
6 Check the tappet clearances and, if necessary, adjust them to the correct dimensions as given i...1328
7 Pour approximately 0,6 litre (1 pint) of clean engine lubricating oil over the rocker assembly ...1328
Coolant pump...1329
Tensioner pulley for fan belts...1329
1 Remove the fan belts, see "How to adjust the tension of the fan belts" on page 27...1329
2 Check that the pulley assembly is retained securely...1329
3 Check the condition of the bearings and renew if necessary...1329
4 Fit the fan belts and alternator belt, "How to adjust the tension of the alternator belt" on pa...1329
Engine damper...1329
Air compressor...1329
Engine fluids...1331
Diesel fuel...1331
Coolant...1331
1 If soft water is not used, the cooling system may be affected by the formation of hard deposits...1332
2 The use of products which are not approved for the cooling system may cause serious problems. C...1332
Lubricating oil...1332
1 Viscosity - Perkins Engines Company Limited recommend the use of SAE15W/40 for all engines that...1332
2 Performance Specification - For heavy duty operation, base load, or extended drain (Eagle Tx on...1332
Recommended oils for Europe...1333
Manufacturer of...1333
lubricating oil...1333
Preferred multi-grade oils which...1333
conform to ACEA E3...1333
Acceptable multi-grade oils which...1333
conform to ACEA E2...1333
Recommended oils for remainder of the world...1334
Manufacturer of...1334
lubricating oil...1334
Mono-grade oils which...1334
conform to ACEA E2...1334
Preferred multi-grade oils...1334
which conform to...1334
ACEA E3...1334
Acceptable multi-grade...1334
oils which conform to...1334
ACEA E2...1334
Warranty...1334
Fault diagnosis...1335
Problems and possible causes...1335
Problem...1335
Possible causes...1335
Checks by the user...1335
Checks by service...1335
personnel...1335
Code list of possible causes...1336
1 The battery capacity is low...1336
2 A bad electrical connection...1336
3 A fault in the starter motor...1336
4 The wrong grade of lubricating oil...1336
5 The starter motor turns the engine too slowly...1336
6 The fuel tank is empty...1336
7 A fault in the stop control...1336
8 A restriction in a fuel pipe...1336
9 A fault in the fuel lift pump...1336
10 A dirty element of the fuel filter...1336
11 A restriction in the air filter or the induction system...1336
12 There is air in the fuel system...1336
13 A fault in the fuel injectors, or the fuel injectors are of the wrong type...1336
14 The cold start system is not used correctly...1336
15 A fault in the cold start system...1336
16 A restriction in the vent of the fuel tank...1336
17 The wrong type or grade of fuel has been used...1336
18 A restriction in the movement of the engine speed control...1336
19 A restriction in the exhaust pipe...1336
20 The engine temperature is too high...1336
21 The engine temperature is too low...1336
22 The tappet clearances are incorrect...1336
23 Too much oil, or oil of a wrong specification is used in a wet type air cleaner...1336
24 Not enough lubricating oil in the sump...1336
25 A defective gauge...1336
26 A dirty element of the lubricating oil filter...1336
27 The fan is damaged...1336
28 A fault in the mountings of the engine or the flywheel housing...1336
29 Too much lubricating oil in the sump...1336
30 A restriction in the air passages or in the water passages of the radiator...1336
31 A restriction in the breather...1336
32 There is insufficient coolant in the system...1336
33 A fault in the exhauster, or there is a leakage in the vacuum pipe...1336
34 A fault in the fuel injection pump...1336
35 A broken drive on the fuel injection pump...1336
36 The timing of the fuel injection pump is incorrect...1336
37 The valve timing is incorrect...1336
38 There is bad compression...1336
39 The cylinder head gasket leaks...1336
40 The valves are not free...1336
41 Wrong high-pressure pipes...1336
42 The cylinder bores are worn...1336
43 A leakage between the valves and the seats...1336
44 The piston rings are not free, or they are worn or damaged...1336
45 The valve stems and/or the guides are worn...1336
46 The crankshaft bearings are worn or damaged...1336
47 The lubricating oil pump is worn...1337
48 The relief valve does not close...1337
49 The relief valve does not open...1337
50 The spring of the relief valve is broken...1337
51 A fault in the suction pipe of the lubricating oil pump...1337
52 A piston is damaged...1337
53 The piston height is incorrect...1337
54 The flywheel housing, or the flywheel, is not aligned correctly...1337
55 A fault in the thermostat or the thermostat is of a wrong type...1337
56 A restriction in the coolant passages...1337
57 A fault in the water pump...1337
58 There is damage to the oil seals (if they are fitted) of the valve stems...1337
59 A restriction in the sump strainer...1337
60 A valve spring is broken...1337
61 The impeller of the turbocharger is damaged or is dirty...1337
62 Leakage of lubricating oil from the oil seal of the turbocharger...1337
63 The induction system leaks (turbocharged engines)...1337
64 Damaged or defective waste-gate (if fitted)...1337
TSD3244E - User’s Handbook (Eagle TX & Eagle 800)...1339
TSD3245E2 - Workshop Manual (2000 Series_6 cylinder diesel engines for industrial applications)...1392
Perkins 2000 Series...1392
Workshop manual...1392
6 cylinder diesel engines for industrial applications...1392
Publication TPD 3245, Issue 2...1392
© Proprietary information of Perkins Group Limited, all rights reserved...1392
The information is correct at the time of print...1392
Published in September 1999 by Technical Publications,...1392
Perkins Engines Company Limited, Lancaster Road, Shrewsbury, Shropshire, SY1 3NX, England...1392
Contents...1394
10 General information...1394
11 Specifications...1394
12 Cylinder head assembly...1395
Rocker cover...1395
Rocker assembly...1395
Tappet clearances...1395
Cylinder head...1395
Valves, valve springs and valve rotators...1395
Fuel injector sleeves...1395
Push rods...1395
13 Piston and connecting rod assembly...1395
Piston and connecting rod assembly...1395
Piston and rings...1396
Connecting rod...1396
Small end bushes...1396
14 Crankshaft assembly...1396
Damper and pulley - early engines...1396
Damper and pulley - new engines...1396
Crankshaft hub and front oil seal...1396
Rear oil seal...1396
Crankshaft...1396
15 Wheelcase and drive assembly...1396
Wheelcase...1396
Backplate...1396
Camshaft gear - bolt-on type...1397
Camshaft gear - integral type...1397
Idler gear...1397
16 Cylinder block assembly...1397
Crankcase...1397
Cylinder liners...1397
Cam followers...1397
Camshaft...1397
17 Engine timing...1397
Fuel injection pump timing...1397
18 Aspiration system...1398
Turbocharger...1398
Turbochargers: OE49342, OE50642, OE51140, and OE51430...1398
Turbocharger: OE50674...1398
Turbochargers: OE52534 and OE52535...1398
Inlet manifold...1398
Exhaust manifold...1398
19 Lubrication system...1398
Lubricating oil filter...1398
By-pass filter/separator...1398
Sump...1398
Lubricating oil pump...1398
Oil pressure relief valve...1399
20 Fuel system...1399
Fuel injectors...1399
Single acting type...1399
Double acting type...1399
Fuel injection pump...1399
Air stop cylinder...1399
21 Cooling system...1399
Radiator...1399
Fan...1399
Fan drive belts...1400
Coolant pump...1400
Thermostat...1400
Oil cooler...1400
22 Flywheel and flywheel housing...1400
Flywheel...1400
Flywheel housing...1400
23 Electrical equipment...1400
Alternator drive belts...1400
Alternator...1400
Engine stop solenoid...1401
24 Auxiliary equipment...1401
Compressor...1401
25 Running-in and test...1401
Running-in and test...1401
26 List of special tools...1401
General information...1402
Introduction...1402
New 2000 Series engines...1402
Cylinder bore identification...1402
Engine identification...1403
General safety precautions...1404
Safety...1405
Engine lift equipment...1405
Asbestos joints...1405
...1405
Dangers from used engine oils...1406
1 Avoid prolonged and repeated contact with used engine oils...1406
2 Wear protective clothing, including impervious gloves where applicable...1406
3 Do not put oily rags into pockets...1406
4 Avoid contaminating clothes, particularly underwear, with oil...1406
5 Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear...1406
6 First aid treatment should be obtained immediately for open cuts and wounds...1406
7 Apply barrier creams before each period of work to aid the removal of mineral oil from the skin...1406
8 Wash with soap and hot water, or alternatively use a skin cleanser and a nail brush, to ensure ...1406
9 Do NOT use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing the skin...1406
10 If a skin disorder appears, medical advice must be taken...1406
11 Degrease components before handling if practicable...1406
12 Where there is the possibility of a risk to the eyes, goggles or a face shield should be worn...1406
Environmental protection...1406
Viton seals...1406
Practical information...1407
Specifications...1410
Basic engine data...1410
Engine...1410
Cooling system...1411
Fuel system...1411
Lubrication system...1411
Induction/exhaust system...1412
Electrical equipment...1412
Auxiliary equipment...1412
Recommended specific applied torques...1413
Recommended nominal applied torques...1415
Cylinder head assembly...1416
Rocker cover...1416
To remove and to fit 12-1...1416
1 Remove the three cap nuts (A) from the top of the cover...1416
2 The cover and joint can now be removed. For certain engines it may be necessary to first remove...1416
1 Remove the joint from the rocker cover and clean the two corresponding faces of the cover and c...1416
2 Fit a new joint to the rocker cover and, ensuring that it is correctly located within the slots...1416
3 Secure the cover with the three cap nuts and check that the joint has not moved. Tighten the ca...1416
Rocker assembly...1417
To remove and to fit 12-2...1417
1 Remove the rocker cover as previously described...1417
2 Unscrew the bolts (A1) which secure the rocker pedestals to the cylinder head...1417
3 Remove the rocker assembly complete and carefully lift out the push rods. Ensure that the tappe...1417
1 Ensure that the tappets have remained correctly positioned in the crankcase and fit the push rods...1417
2 Check that the lower ends of the push rods are located inside the tappets...1417
3 Fit the rocker assembly with the tappet adjusting screws seating in the upper end of the push r...1417
4 Screw in the pedestal securing bolts and tighten evenly, outwards from the centre, to a torque ...1417
5 Check and adjust the tappet clearances as given on page 27...1417
6 On completion of tappet clearance adjustment, fit the rocker covers...1417
Tappet clearances...1418
To check and to adjust 12-3...1418
1 Remove the rocker covers...1418
2 Turn the crankshaft in the normal direction of rotation, anti-clockwise when viewed on the flyw...1418
3 Continue to turn the engine and adjust the remainder of the tappet clearances in the sequence g...1418
4 Fit the rocker covers...1418
Cylinder head...1419
To remove and to fit 12-4...1419
1 Drain the cooling system...1419
2 Remove the air inlet ducting between the turbocharger and the induction manifold...1419
3 Remove the rocker cover(s), operation 12-1...1419
4 Remove rocker assembly and push rods, operation 12-2...1419
5 Unscrew and remove the set of high-pressure fuel pipes. Do not remove the pipes individually, t...1419
6 Remove the coolant rail/thermostat housing and the fuel filter assembly...1419
7 Unscrew and remove the turbocharger(s). Remove the inlet and exhaust manifolds...1419
8 Remove the fuel spill return pipes from the injectors. Unscrew the injector clamping bolts and ...1419
9 Fit suitable caps or plugs to the injector nozzles, fuel pump delivery valve holders and other ...1419
10 Unscrew and remove the cylinder head securing bolts and washers together with the nut from the...1419
11 Using the lifting bar, 21825 816, remove the cylinder head and place it on a clean surface. Pr...1419
12 Remove the cylinder head gasket and the coolant transfer bobbins using bobbin removal tool, 21...1419
1 Clean the face of the cylinder head and the top surface of the crankcase. Check that the cylind...1420
2 Fit a new cylinder head gasket over the roll pins in the crankcase top face, ensuring the side ...1420
3 Fit the transfer bobbins with new sealing rings and place in position...1420
4 Ensure that the face of the head is clean and, using lifting bar, 21825 816, carefully lower th...1420
5 A light application of oil must be applied under the head of each cylinder head bolt and also t...1420
6 Screw the bolts in by hand to ensure the correct location. Always place the bolts in position, ...1420
7 Tighten the bolts and nut (fitted to early engines) as follows:...1420
a Tighten all of the bolts in the sequence shown (A) to a torque of 136 Nm (100 lbf ft)...1420
b Tighten all of the bolts in the sequence shown (A) to a torque of 204 Nm (150 lbf ft)...1420
c Tighten ONLY the bolts shown in the black circles, in the sequence shown (A), by an additional ...1420
8 Fit the rocker gear and push rods. Adjust the tappet clearances, see page 27, and fit the rocke...1420
9 Fit the inlet manifold/charge cooler assembly. Do not fit the ducting to the turbocharger(s) at...1420
10 Fit the exhaust manifold and tighten the securing bolts to a torque of 45 Nm (33 lbf ft). Fit ...1420
11 Renew the sealing rings (A) in the coolant rail/ thermostat housing and fit the assembly...1421
12 Fit the fuel filter assembly...1421
13 Remove any blanking plugs or caps and fit the injectors. Tighten the clamping bolts to a torqu...1421
14 Fit the fuel spill pipes using new washers with the banjo bolts...1421
15 Remove the blanking covers from the fuel injection pump and fit the high-pressure fuel pipes a...1421
16 Fit the air ducting between the turbocharger and the induction manifold/charge cooler...1421
17 Refill the cooling system to the correct level...1421
Procedure for retightening of the cylinder head bolts 12-5...1422
1 Remove the rocker covers and the rocker assemblies...1422
2 Wipe clean the nuts and the heads of the bolts which retain the cylinder heads...1422
3 Make a temporary mark on each nut and on the head of each bolt, and also on the cylinder heads...1422
4 Work on one bolt or nut at a time, use the sequence shown (A) and proceed as follows:...1422
a Remove the bolt or nut. Lubricate lightly the threads and the lower face of the bolt or the nut...1422
b Tighten the bolt or nut to 204 Nm (150 lbf ft). Continue in the correct sequence...1422
a Tighten these bolts in the correct sequence by a further 40 of angular movement or until the m...1422
5 Fit the rocker assemblies, tighten the bolts evenly and progressively to a torque of 41 Nm (30 ...1422
6 Check and, if necessary, adjust the tappet clearances, operation 12-3...1422
7 Pour approximately 0,6 litre (1 pint) of clean engine lubricating oil over the rocker assemblie...1422
To dismantle and to assemble 12-6...1423
1 Clean the face of the cylinder head before removing the valves and check the depth of the valve...1423
2 Lay the cylinder head, flame face down, on a bench with a soft surface and remove the valves by...1423
3 Compress the valve springs in turn (A) and remove the collets to release the springs. Lift off ...1423
4 Stand the cylinder head in a suitable position to remove the valves. Identify the valves to ens...1423
1 Clean all components and renew all seals...1424
2 Fit the lower spring seats/valve rotators (A1) over the exhaust valve guides...1424
3 Renew the valve stem seals (A3) as follows: oil the valve guide and fit the seal to the inserti...1424
4 Fit the seating washers (A2) over the inlet valve guides...1424
5 Lightly lubricate the valve stems and fit the valves to their respective guides...1424
6 Carefully lay the cylinder head, flame face down, on a soft surface. Assemble the springs (A4) ...1424
7 Check carefully to ensure that all of the collets are located correctly...1424
To clean and to inspect the cylinder head 12-7...1425
To renew a valve spring with the cylinder head installed 12-8...1425
1 Remove the relevant rocker cover, operation 12-1, and turn the engine in the normal direction o...1425
2 Slacken the tappet screws of this cylinder, remove the rocker assembly and lift out the push rods...1425
3 Cover the push rod holes to ensure that no components can drop in and fit the valve spring comp...1425
4 Compress and remove the springs and other components in the manner described previously with th...1425
5 Renew items as necessary and fit the springs and other components. Remove the covers from the p...1425
6 Fit the push rods and the rocker assembly. Check and reset the tappet clearances, operation 12-...1425
To correct a valve seat 12-9...1426
1 Inspect the inserts for erosion and cracks. If it is necessary to correct the inserts, lightly ...1426
2 After the inspection and correction of a valve seat and the relevant valve, fit the valve into ...1426
3 To ensure that the valve is fitted in its correct position, the number of the cylinder and the ...1426
To remove a valve seat insert 12-10...1427
1 Secure the cylinder head on a milling machine, and use a slot drill of approximately 10 mm (3/8...1427
2 Use a flat chisel, at the point which is indicated by the arrow (A2) and in the direction of th...1427
3 Remove the insert and check that the recess is clean and that there is no damage. Ensure that a...1427
To fit a valve seat insert 12-11...1427
1 Replacement inserts are available in either standard or 0,050 mm (0.002 in) oversize diameters...1427
2 Ensure that the counter bores in the cylinder head are clean. The insert should be frozen in li...1427
3 Fit the insert immediately, using the special tool 21825 869...1427
4 Check, using a 0,04 mm (0.0015 in) feeler gauge, that the insert is fully seated...1427
To inspect the valve guides 12-12...1428
To renew a valve guide 12-13...1428
1 Working from the flame face side of the cylinder head drive out the guide using drift, 21825 752...1428
2 Ensure that the new guide is clean and free from burrs. Freeze the guide in liquid nitrogen, if...1428
3 Exhaust guides must be entered with the end machined for the valve stem seal leading. Inlet gui...1428
4 Press fit the new guide (A1) using the replacer tool, 21825 763 (A2), and a hand press. Stop wh...1428
5 Use the reamer, 21825 748, by hand, to finish the guide bore (B)...1428
6 Recut the valve seat to the relevant angle. See operation 12-9...1428
Valves, valve springs and valve rotators...1429
To remove and to fit 12-14...1429
1 Remove the cylinder heads, operation 12-4...1429
2 Remove the valves, the valve springs and the valve rotators, operation 12-6...1429
1 Fit the valves, the valve springs and the valve rotators, operation 12-6...1429
2 Fit the cylinder heads, operation 12-4...1429
To clean and to inspect 12-15...1429
1 Clean the valves thoroughly and inspect the head of each valve for cracks or other damage. Chec...1429
2 Check that the valves are not dished by use of a straight edge and a feeler gauge. Discard the ...1429
3 Pitted or damaged valve seat faces may be reclaimed by removing the minimum amount of material ...1429
4 Check both inlet and exhaust valves with gauge, 21825 754 (A1), and a straight edge, to determi...1429
5 If new valves are fitted, the cylinder number and position should be etched near to the top of ...1429
6 Certain early engines have valve rotators (rotocoils) fitted beneath the exhaust valve springs...1429
7 Inspect the tips of the valve stems. If the wear marks indicate that the valve has not rotated,...1429
8 Two springs are fitted over each valve. For ease of identification the exhaust valve springs ar...1429
Fuel injector sleeves...1430
To remove and to fit 12-16...1430
1 Remove the high-pressure fuel pipes: For new 2000 series engines remove the set of high-pressur...1430
2 Remove the relevant low pressure fuel pipes and remove the injector assembly. To remove a tight...1430
3 Place the injector sleeve removal tool, 21825 908, in the slots in the top of the sleeve, unscr...1430
4 Remove and discard the rubber seal from the cylinder head and the copper washer from inside the...1430
1 Fit a new ‘O’ ring seal into the groove in the cylinder head and lubricate with a smear of T 82...1431
2 Lubricate the threaded end of the sleeve with Hylomar Universal sealing compound...1431
3 Smear the outside of the sleeve with T8210 grease and screw into position by hand to ensure cor...1431
4 Using the tool, 21825 908, tighten the sleeve to a torque of 33 Nm (24 lbf ft)...1431
5 Fit a new copper washer over the nozzle and a new rubber seal over the injector barrel...1431
6 Apply an even layer of anti-seize compound (‘Morris K72’ or equivalent) to the outside of the f...1431
7 Slide the injector into position in the cylinder head. The rubber seal will become enclosed in ...1431
8 Fit the distance piece, the injector clamp and the securing bolts. Tighten evenly to a torque o...1431
9 Fit the high-pressure fuel pipes as a complete set. Do NOT allow the pipes to become bent. Tigh...1431
Push rods...1432
To remove and to fit 12-17...1432
1 Remove the rocker covers, operation 12-1 and remove the rocker assemblies, operation 12-2...1432
2 Withdraw the push rods and put them in storage in the sequence in which they were removed...1432
1 Fit the push rods into their cam followers, ensure that they are fitted to the locations from w...1432
To inspect 12-18...1432
Fits and clearances - Rocker assemblies...1433
Fits and clearances - Cylinder heads and valve assemblies...1434
Piston and connecting rod assembly...1436
General description...1436
1 The pistons (A) are cast in a low expansion type aluminium alloy with an inserted cast iron top...1436
Piston and connecting rod assembly...1438
To remove and to fit 13-1...1438
1 Drain the coolant and lubricating oil...1438
2 Remove the cylinder head, operation 12-4...1438
3 Remove the sump, operation 19-3...1438
4 Remove the piston cooling jet (A) from the bottom of the relevant cylinder...1438
5 Unscrew the big end nuts and remove the big end cap bearing and bolts...1438
6 Push the piston and connecting rod carefully out through the top of the bore...1438
7 The rod and piston must be kept together with all the related parts as an assembly for the rele...1438
1 Check that the piston and connecting rod are correctly assembled and that the piston and cylind...1438
2 Turn the crankshaft until the crank pin, relevant to the bore in which the piston is to be fitt...1438
3 Fit the upper half of the big end bearing to the connecting rod, ensuring that the location tan...1438
4 Ensure that the piston cooling jet is removed from the bottom of the bore...1438
5 Use the sleeve, 21825 784 (B1), to fit the assembly into the bore with the ‘FRONT’ marking on t...1438
6 Ensure that the flats on the big end bolts are correctly located against the flats on the conne...1439
7 Turn the crankshaft until the piston is at TDC and measure the clearance of the piston crown be...1439
8 Fit the piston cooling jet, complete with new ‘O’ ring seal. If necessary, turn the engine to e...1439
9 Fit the sump, operation 19-3...1439
10 Fit the cylinder heads, operation 12-4...1439
11 Fill the coolant system to the correct level with the approved coolant mixture...1439
12 Fill the sump to the correct level with the correct grade of lubricating oil...1439
To dismantle and to assemble 13-2...1440
1 Use piston ring pliers, 21825 793, to remove the rings from the piston...1440
2 Make a note of the relationship between the ‘FRONT’ marking on the piston and the correlation m...1440
3 Remove the gudgeon pin circlips and push out the pin sufficiently to release the piston from th...1440
1 Fit the rings to the piston ensuring that the non- reversible rings are fitted correctly...1440
2 Heat the piston to approximately 20C (68F). Oil the small end bushes and assemble the rod to ...1440
3 Set the gaps of the piston rings at equidistant intervals as shown (A) before the assembly is f...1440
Piston and rings...1441
To inspect 13-3...1441
1 De-carbonise the piston by soaking in a proprietary solvent such as ‘Ardrox 691’...1441
2 Check the piston for damage or wear. Use a new piston ring as a guide when checking for wear in...1441
3 Crack test the gudgeon pin and check for a push fit in the piston at 20C (68F). If the pin is...1441
4 Check the piston rings for damage, scores, wear, and signs of leakage. Discard the top ring if ...1441
5 The spring in the oil control ring gives a radial pressure of 1035 kN/m· (150 lb/in·) when new ...1441
6 Place the rings in turn in an unworn portion of their own liner to check the ring gaps. Discard...1441
Connecting rod...1441
To inspect 13-4...1441
1 Crack test the rod assembly electromagnetically and inspect the bolts for signs of wear or dama...1441
2 Check the small end bushes and renew as necessary, operation 13-5...1441
3 Check the alignment of the big and small end bores in two planes. Do NOT attempt to correct a b...1441
4 Carefully inspect the bearings for cracks, scores, wear and embedded foreign material. If there...1441
Small end bushes...1442
To renew 13-5...1442
1 Press out the unserviceable bushes. Remove any burrs from the eye of the connecting rod and ens...1442
2 New bushes should be drawn in one from each side. A tool, 21825 814 (A), is available for this ...1442
1 Press out the unserviceable single small end bush. Remove any burrs from the eye of the connect...1442
2 Press a new bush into the connecting rod, ensuring that the oil hole is correctly aligned with ...1442
3 Cut off the protruding edges of the bush and dress up with a smooth file until flush with the s...1442
4 Secure the connecting rod in a boring machine and bore the bush to the correct diameter:...1442
Fits and clearances...1443
Fits and clearances...1444
Crankshaft assembly...1448
General description...1448
Damper and pulley - early engines...1449
To remove and to fit 14-1...1449
1 Slacken the belt tensioner pulley and remove the drive belts...1449
2 Slacken and remove the bolts which secure the pulley and damper to the hub...1449
3 Withdraw the pulley, the hub nut locking plate, the spacer and the damper, noting the sequence ...1449
1 Assemble the damper, the spacer, the hub nut locking plate and the pulley to the crankshaft, in...1449
2 Fit the sixteen setbolts and spring washers. Tighten the setbolts evenly to a torque of 41 Nm (...1449
3 Refit the drive belts, adjust to the correct tension, and tighten the belt tensioner pulley...1449
Damper and pulley - new engines...1450
To remove and to fit 14-2...1450
1 Remove the alternator belt. Slacken the tensioner pulley for the fan belts and remove the fan b...1450
2 Slacken and remove the bolts which retain the pulley and the damper on the crankshaft hub...1450
3 Remove the pulley and the damper...1450
1 Fit the damper and the pulley to the crankshaft. The pulley fits over the large crankshaft nut...1450
2 Fit the damper and the pulley and fit the 16 bolts and spring washers. Tighten the bolts to a t...1450
3 Fit the drive belts and adjust them to the correct tension. Tighten securely the tensioner pull...1450
Crankshaft hub and front oil seal...1451
To remove and to fit 14-3...1451
1 Remove the pulley and damper as previously instructed in this section...1451
2 Using the spanner, 21825 807, and a suitable hammer, unscrew and remove the hub securing nut...1451
3 Withdraw the hub and front cone...1451
4 Carefully lever out and discard the front oil seal...1451
1 Check the crankshaft hub splines and cone for signs of wear, and renew if necessary...1451
2 Fit a new oil seal to the wheelcase. Ensure that the seal is positioned correctly, as shown (A)...1451
3 Apply a light film of clean engine oil to the hub splines prior to fitting the hub and cone...1451
4 Check the hub nut threads, lightly oil, and fit the nut by hand...1451
5 Tighten the nut to 950 Nm (700 lbf ft) by torque spanner or, alternatively, by the following me...1451
a Use the spanner to tighten the nut as fully as possible by hand...1451
b Scribe suitable alignment marks on the hub and nut and use a hammer to tighten the nut by a fur...1451
c If difficulties are encountered when fitting the locking plate, the nut may be tightened by the...1451
6 Fit the pulley and damper, see operation 14-1 or operation 14-2...1451
To fit a new oil seal to a wheelcase removed from the engine 14-4...1452
1 Ensure the seal housing in the wheelcase is free from oil and other possible debris...1452
2 Support the wheelcase on a flat horizontal surface under a hand press, ensuring sufficient clea...1452
3 Place the seal at the entrance to the bore with the part number facing outwards...1452
4 Cover the seal completely with a flat metal plate and operate the press until light bottoming o...1452
5 Wipe away any excess dry sealant which has been displaced from the seal outer casing...1452
6 Do NOT remove the plastic mandrel until the wheelcase has been fitted to the engine...1452
Rear oil seal...1453
To remove and to fit 14-5...1453
1 Drain the engine oil and remove the flywheel, operation 22-1...1453
2 Use a centre punch to make two holes in the edge of the seal at diametrically opposite position...1453
3 Select two suitable self-tapping screws, complete with plain washers, and fit the screws to the...1453
4 Clean the bore of the flywheel housing, or oil seal housing, which was in contact with the old ...1453
1 Ensure that the flywheel location dowel is fitted to the crankshaft. Fit the guide part of the ...1453
2 Before the oil seal is fitted, check the guide and the crankshaft again for dirt or for a rough...1453
3 Slide the collar part of the tool onto the guide until the face of the collar is against the ou...1453
4 Remove the complete tool. The tool should be kept assembled to protect the guide part...1453
5 Fit the flywheel, operation 22-1...1453
Crankshaft...1454
To remove and to fit 14-6...1454
1 Drain the engine lubricating oil and coolant whilst the engine is still installed...1454
2 Remove the unit and fit it to the engine build stand, 21825 993. See operation 16-1...1454
3 Remove the sump and oil pump, operation 19-3 and operation 19-4...1454
4 Remove the coolant pump, operation 21-5 and the thermostat housing/coolant rail assembly...1454
5 If fitted, remove the compressor, operation 24-1...1454
6 Remove the fuel injection pump, operation 20-10...1454
7 Remove the starter motor, operation 23-3...1454
8 Remove the alternator, operation 23-2...1454
9 Remove the flywheel housing, operation 22-3...1454
10 If fitted, remove the crankshaft rear seal housing...1454
11 Remove the crankshaft hub and damper assembly, operation 14-3 and operation 14-1 or operation ...1454
12 Remove the wheelcase, operation 15-1...1454
13 Unscrew the idler gear retaining bolt and withdraw the gear and thrust plate...1454
14 Remove the camshaft gear or, for engines with an integral gear, remove the camshaft, operation...1454
15 If fitted, remove the fuel pump adapter plate and discard the ‘O’ rings. Remove the wheelcase ...1454
16 Disconnect the connecting rods from the crankshaft. Ensure that the caps and shell bearings ar...1454
17 Slide the piston and connecting rod assemblies into the bores until they are clear of the cran...1454
18 Remove the main bearing caps, if necessary using the puller, 21825 806, and remove the lower h...1454
19 Using suitable lifting equipment, lift out the crankshaft and remove the upper half of the mai...1454
1 Lightly oil the upper halves of the main bearing shells and fit them to the crankcase...1454
2 Carefully lower the crankshaft into position...1454
3 Fit the main bearing caps as given in operation 16-2, paragraphs 3 and 4. Check that the cranks...1454
4 Withdraw each piston and connecting rod assembly from its bore and fit the upper half of the bi...1454
5 Fit the backplate, complete with a new gasket and, where necessary, the fuel pump adapter plate...1454
6 Turn the engine until No.1 piston is at the TDC position. Fit the camshaft and idler gears with...1454
7 Fit the wheelcase...1454
8 Fit the crankshaft hub and damper assembly, operation 14-3 and operation 14-1 or operation 14-2...1454
9 For early 2000 series engines, fit the crankshaft rear seal housing...1454
10 Fit the flywheel housing, operation 22-3...1454
11 Fit the alternator, operation 23-2...1454
12 Fit the starter motor, operation 23-3...1454
13 Fit the fuel injection pump, operation 20-10...1454
14 If necessary, fit the compressor, operation 24-1...1454
15 Fit the coolant pump, operation 21-5 and the thermostat housing/coolant rail assembly...1455
16 Fit the oil pump and sump, operation 19-4 and operation 19-3...1455
17 Remove the engine from the build stand, operation 16-1...1455
18 Refill with clean engine oil of the correct grade and specification...1455
19 Fill the coolant system to the correct level with the approved coolant mixture...1455
To inspect 14-7...1455
1 Thoroughly clean the assembly...1455
2 Inspect the pinion and oil pump drive gear assembly for wear and damage...1455
3 Where relevant, extract all the oil reservoir plugs: tap each plug in slightly, remove the reta...1455
4 Clean all the components with special attention to the crankshaft oilways...1455
5 Perform a crack test on the shaft, pinion and oil pump drive gear, preferably using the electro...1455
6 Where relevant, refit the oil reservoir plugs, complete with new ‘O’ rings, as follows: Oil the...1455
a Minus 0,51 mm (0.020 in)...1455
b Minus 1,02 mm (0.040 in)...1455
Fits and clearances...1456
Wheelcase and drive assembly...1458
General description...1458
Wheelcase...1459
To remove and to fit 15-1...1459
1 Drain the engine coolant...1459
2 Remove the following components:...1459
a (a) Sump - see operation 19-3...1459
b Alternator - see operation 23-2...1459
c Belt tensioner bracket...1459
d Crankshaft hub - see operation 14-3...1459
e Coolant pump - see operation 21-5...1459
f Compressor (if fitted) - see operation 24-1...1459
3 Remove the wheelcase retaining bolts and withdraw the casing...1459
4 Discard all gaskets and clean the joint faces...1459
1 Renew all gaskets...1459
2 Fit the wheelcase, complete with a new gasket...1459
3 Fit the components removed in paragraph 2 of the removal sequence...1459
4 Refill the coolant system...1459
Backplate...1459
To remove and to fit 15-2...1459
1 Remove the wheelcase, operation 15-1...1459
2 Remove the fuel injection pump assembly, operation 20-10...1459
3 Remove the coolant rail, thermostat housing and the radiator by-pass tube from the top of the b...1459
4 Turn the engine until No.1 piston is at TDC with the relevant mark on the flywheel aligned with...1459
5 Bend back the tabs on the camshaft gear locking plate and slacken the retaining bolts. The cams...1459
6 Remove the idler gear retaining bolt and withdraw the gear and thrust washer...1459
7 For engines with removable camshaft gears: Unscrew the camshaft gear retaining bolts and remove...1459
8 If fitted, remove the fuel pump adaptor housing from the backplate and discard the ‘O’ rings...1459
9 Unscrew the three backplate retaining bolts and carefully tap the plate free from the dowels...1459
10 Discard the gasket and clean the joint faces...1459
11 Withdraw the oil transfer tube from the backplate and discard the ‘O’ ring...1459
1 Fit the oil transfer tube (A1) to the backplate, complete with a new ‘O’ ring (A2)...1460
2 Fit a new gasket over the two dowels in the front of the crankcase, fit the backplate and secur...1460
3 Fit the camshaft thrust washer and tighten the setscrews evenly to a torque of 54 Nm (40 lbf ft)...1460
4 Fit the camshaft gear (B1), locating it on the roll pin in the end of the camshaft. The bolt ho...1460
5 Slide the idler gear (B2) on to its axle, with the timing marks aligned with the corresponding ...1460
6 Fit the idler gear thrust plate (B3) and securing bolt (B4). Ensure that the slot in the plate ...1460
7 Tighten the camshaft gear retaining bolts to a torque of 61 Nm (45 lbf ft), and bend over the l...1460
8 For early engines: fit the fuel pump adaptor (A2) and renew the two ‘O’ ring seals (A1 and A3)...1461
9 Fit the fuel injection pump, operation 20-10...1461
10 Fit the radiator by-pass tube, thermostat housing and coolant rail, renewing all gaskets and ‘...1461
11 Fit the wheelcase, operation 15-1...1461
Camshaft gear - bolt-on type...1462
To remove and to fit 15-3...1462
1 Remove the wheelcase, operation 15-1...1462
2 Turn the engine until No.1 piston is at TDC with the relevant mark on the flywheel aligned with...1462
3 Remove the idler gear (A1)...1462
4 If fitted, bend back the locking plate tabs, remove the retaining bolts and carefully lever off...1462
5 Inspect the gear for worn or damaged teeth and renew if necessary...1462
6 Do not turn the engine from its present position...1462
1 Fit and secure the camshaft gear (A3) to the camshaft with the timing mark aligned with the cor...1462
2 Fit the idler gear...1462
3 Check that the gear backlash is within limits. Refer to Fits and clearances on page 77. If the ...1462
4 Fit the locking plate, if one was previously fitted, fit the retaining bolts, tighten them to a...1462
5 Fit the wheelcase, operation 15-1...1462
Camshaft gear - integral type...1463
To remove and to fit 15-4...1463
1 Remove the cam followers, operation 16-6...1463
2 Remove the idler gear, operation 15-6...1463
3 Remove the camshaft, operation 16-8...1463
4 Place the camshaft in a hydraulic press with the camshaft gear uppermost. Support the gear unde...1463
1 Support the camshaft in a suitable press. Fit the thrust plate to the camshaft. Ensure that the...1463
2 Insert a new key in the camshaft keyway...1463
3 Heat the gear in a pre-heated oven at 300oC for a minimum of 15 minutes...1463
4 Place the gear on the camshaft while still hot and press it onto the camshaft until the distanc...1463
5 Fit the camshaft, operation 16-8...1463
To inspect 15-5...1464
1 Inspect the camshaft gear journal for burrs or other damage. If the damage cannot be removed by...1464
2 Inspect the bore of the gear for burrs or other damage. If the damage cannot be removed by the ...1464
Idler gear...1465
To remove and to fit 15-6...1465
1 Remove the wheelcase, operation 15-1...1465
2 Turn the engine until No.1 piston is at TDC with the relevant mark on the flywheel aligned with...1465
3 Check and note the end float of the idler gear...1465
4 Check the gear for excessive play on the axle...1465
5 Remove the securing bolt and thrust plate...1465
6 Withdraw the gear and check for worn or damaged teeth...1465
7 Do not turn the engine from its present position...1465
1 Slide the gear onto the axle, with the timing marks aligned with the relevant markings on the c...1465
2 For new 2000 series engines: Fit the idler gear thrust plate and securing bolt. Tighten the bol...1465
3 Check the backlash of the idler gear, see Fits and clearances on page 77. If a new gear has bee...1465
4 Fit the wheelcase,operation 15-1...1465
To set the gear backlash 15-7...1466
1 The camshaft gear and the crankshaft gear must be fitted and the FIP drive gear must be fitted,...1467
2 Fit the idler gear axle (A1) without the dowels, fit spring washers to the bolts and tighten th...1467
3 Fit the gear and check the backlash at four equally spaced points on its circumference between ...1467
4 Adjust the position of the idler gear axle to achieve a backlash of 0,05 to 0,15 mm (0.002 to 0...1467
5 Remove carefully the idler gear, ensure that the idler gear axle is not disturbed; tighten the ...1467
6 Fit the reaming jig, 21825 999, over the idler gear axle, fit the relevant location pin into on...1467
7 Fit the relevant locating pin to the dowel hole and remove the other locating pin. Ream the sec...1467
8 Remove the locating pin and the reaming jig. Ensure that the dowel holes are clean. Fit new dow...1467
9 Use a centre punch to distort the dowel holes similar to that shown (A3)...1467
10 Fit the idler gear, operation 15-6...1467
Fits and clearances...1468
Cylinder block assembly...1470
General description...1470
Crankcase...1471
To fit to and to remove from a build stand 16-1...1471
1 Disconnect the batteries...1471
2 Close the valves and disconnect the pipes for the fuel supply and the fuel return...1471
3 Drain the coolant system (refer to the User’s Handbook TSD 3215), remove the radiator, operatio...1471
4 Drain the lubricating oil from the engine by the removal of the drain plugs from the base of th...1471
5 Remove the fan, operation 21-2...1471
6 Remove the air cleaner assembly and the ducting to the turbocharger...1471
7 If a compressor is fitted, remove the compressor air filter and associated pipework. Disconnect...1471
8 Remove the turbocharger exhaust outlet pipe and, where applicable, the diffuser. Prior to remov...1471
9 Remove the alternator and drive belt...1471
10 Slacken the belt tensioner and remove the belts and the tensioner assembly...1471
11 Use the filter wrench, 21825 825, to remove the oil filter canisters. Disconnect all relevant ...1471
12 Remove the turbocharger(s), complete with the oil supply and drain pipework...1471
13 Remove the oil filler and the dipstick tube assemblies...1471
14 Fit the mounting brackets to the crankcase. Using a crane and the lifting beam, 21825 821, sup...1471
1 Fit the lift adaptor, 21825 821, to the engine, use a suitable hoist to remove the engine from ...1471
2 Fit the oil cooler assembly and its coolant pipes, secure pipes with hoses and hose clips. Fit ...1471
3 Fit the engine stop solenoid, refer to section 23 for setting details...1471
4 Fit new oil filter canisters as detailed in section 4 of the User’s Handbook, TSD 3215...1471
5 Fit the oil by-pass filter together with all the relevant pipework...1471
6 Fit the fan, operation 21-2...1471
7 Connect the exhaust pipes...1471
8 Fit the radiator, operation 21-1...1471
9 Fit the air cleaner assembly and connect the ducting to the turbocharger...1471
10 Set the fuel injection pump timing, operation 17-2...1471
11 Fill the lubrication system to the correct level with clean engine lubricating oil, see User’s...1471
12 Fill the coolant system to the correct level, see User’s Handbook TSD 3215...1471
13 Connect the fuel supply...1471
14 Connect the batteries...1471
15 Eliminate air from the fuel system, operation 20-11...1471
To dismantle and to assemble 16-2...1472
1 Fit the assembly of the engine to a build stand, operation 16-1...1472
2 Remove the exhaust manifolds...1472
3 Remove the main pulley and damper from the crankshaft hub. Unscrew the crankshaft nut and remov...1472
4 Disconnect and remove the low pressure fuel pipes. Unscrew the fuel filter and remove the filte...1472
5 Remove the coolant rail and the thermostat housing...1472
6 Disconnect the coolant pump pipework. Unbolt the pulley from the coolant pump and remove the pump...1472
7 Remove the air inlet manifold/charge cooler and associated pipework...1472
8 Remove the high-pressure fuel pipes, unions and shrouds...1472
9 Remove the rocker covers and fuel injectors...1472
10 Remove the rocker gear and pushrods. The pushrods must be stored in the correct sequence to en...1472
11 Fully slacken the tappet adjusting screws before removing the rocker pedestal bolts. Slacken t...1472
12 Remove the starter motor and solenoid assembly, operation 23-3...1472
13 Remove the tappet cover, gasket, baffle plate and the rocker oil feed pipe. Lift out the cam f...1472
14 Remove the flywheel, operation 22-1, use the lifting bracket 21825 817. Remove the flywheel ho...1472
15 Rotate the build stand until the sump is uppermost and remove the sump...1472
16 Remove the wheelcase, operation 15-1...1472
17 Remove the oil transfer pipes, the connections and the suction intake assembly. Remove the oil...1472
18 Remove the rear end oil seal housing - not fitted to new 2000 series engines...1472
19 Disconnect and remove the stop solenoid. Remove the fuel injection pump drive gear and remove ...1472
20 For engines fitted with an integral camshaft gear, remove the camshaft as given in operation 1...1472
21 Remove the backplate and rotate the build stand until the engine is horizontal. Remove the pis...1472
22 Remove the lateral bolts of the main bearing caps and extract the bearing caps, if necessary u...1472
1 Fit the mounting brackets to the crankcase and secure the crankcase in the engine build stand, ...1473
2 Oil the camshaft bearing housing and carefully slide the camshaft into position...1473
3 Rotate the build stand until the sump mounting face is uppermost. Fit and oil the upper halves ...1473
4 Apply a light coat of oil to the threads of the main bearing cap bolts. Fit all the bolts but d...1473
5 Check that the crankshaft rotates freely and measure the crankshaft end float, it must be betwe...1473
6 Ensure that the cylinder liners have been cleaned and inspected as given in operation 16-5 and ...1473
7 Measure and record the liner flange protrusion above the crankcase top face at four equidistant...1474
8 Use ‘Engineers blue’ to check the contact between the liner flanges and their seating faces. To...1474
9 When the protrusion check for the cylinder liners is satisfactory, remove the liners and ensure...1475
10 Fit the cylinder liners, operation 16-4...1475
11 Rotate the build stand until the engine is almost horizontal. Assemble the pistons and connect...1475
12 Fit the upper half of the big end bearing to the connecting rod, ensuring that the location ta...1475
13 Fit the lower half of the bearing into the big end cap ensuring correct location, and lubricat...1475
14 Fit the six piston cooling jets, complete with new ‘O’ ring seals, secure each with a bolt and...1475
15 Rotate the build stand until the engine is upright. Turn the crankshaft until the piston is at...1475
16 Fit the two rocker gear oil feed studs and the blanking plug, complete with new sealing washer...1475
17 Fit a new ‘O’ ring seal to the oil transfer tube and position the tube in the crankcase front ...1476
18 Fit the fuel injection pump adaptor using new ‘O’ rings on the spigot and between the adaptor ...1476
19 Lightly smear the camshaft journals and bearing surfaces with clean engine oil and insert the ...1476
20 For engines with the bolt-on type of camshaft gear proceed as follows:...1476
21 Fit the fuel injection pump drive gear and secure with retaining plate and bolts...1476
22 For new 2000 series engines: Fit the dowel for the idler gear axle, fit the axle, fit the gear...1476
23 Ensure that the crankcase and cylinder head flame faces are clean and dry. Fit the coolant bob...1476
24 Position the lifting eyes. A light application of oil must be applied under the head of each c...1477
25 Screw the bolts in by hand to ensure the correct location. Always place the bolts in position,...1477
26 Align the heads by temporarily fitting the inlet manifold without the gasket and, using the se...1477
a Tighten all bolts in the sequence shown (A) to a torque of 136 Nm (100 lbf ft)...1477
b Tighten all bolts in the sequence shown (A) to a torque of 204 Nm (150 lbf ft)...1477
c Tighten ONLY the bolts in the black circles, in the sequence shown (A), by an additional angle ...1477
27 Lightly oil the cam followers and fit them to their relevant positions in the crankcase. Fit t...1477
28 Fit the push rods and assemble the rocker gear. Refer to section 11 for torque settings. To fa...1478
29 Re-check each clearance after tightening the lock nut of the adjusting screw to 40 Nm (30 lbf ...1478
30 Fit the air inlet manifold/charge cooler assembly, use new gaskets at the joint face. Fit the ...1478
31 Fit the rear oil seal housing and oil seal to the crankcase rear face...1478
32 Fit the oil pump dowels and, where necessary, the original shims, and fit the oil pump complet...1478
33 Fit the suction intake assembly, the oil transfer pipes and connections to the oil pump and cr...1479
34 Fit the wheelcase complete with a new gasket at the joint face. Before tightening the securing...1479
35 Fit the sump guide studs, 21825 812, apply two lines of Hylogrip sealant along the joints wher...1479
36 With the crankcase in the upright position, fit the flywheel housing as follows:...1479
37 Fit the flywheel guide studs, 21825 802, to the crankshaft, position the flywheel using liftin...1479
38 Fit and secure the starter motor assembly...1479
39 Fit the rear cone, the crankshaft hub, the front cone and the crankshaft nut, ensure that the ...1479
40 Fit the fuel injection pump, operation 20-10...1480
41 Fit the fuel injectors, operation 20-1. Fit both rocker covers complete with new gaskets...1480
42 Blow through high pressure fuel pipes with dry compressed air before proceeding: Loosely fit t...1480
43 Assemble the coolant rail to the thermostat housing, using new ‘O’ ring seals on all connectio...1480
44 Fit the fuel filter bracket and fit the low pressure fuel pipes, check all pipes for cleanline...1480
45 Position a new coolant pump gasket and fit the coolant pump, connect the relevant hoses and co...1480
46 Fit the crankshaft damper, locking plate and main pulley and secure with bolts and spring wash...1480
47 Assemble the exhaust manifold and, using new gaskets, bolt the assembly to the cylinder heads...1480
48 Mount the compressor, complete with drive gear, on the rear of the backplate, use a new gasket...1480
49 Connect the coolant pipework between the crankcase and the compressor and the compressor and t...1480
50 Fit the oil filler assembly, complete with a new gasket. Fit the dipstick assembly...1480
51 Secure the alternator mounting bracket and alternator to the coolant pump outlet connection, f...1480
52 Fit the belt tensioner assembly, then the alternator drive belt and the three main drive belts...1480
53 Apply a light coat of anti-seize compound to the mounting stud threads and assemble the turboc...1480
54 Remove the engine from the build stand, operation 16-1...1480
To inspect 16-3...1481
Cylinder liners...1482
To remove and to fit 16-4...1482
1 Drain cooling and engine lubrication systems...1482
2 Remove the cylinder head/s, operation 12-4...1482
3 Remove the sump, operation 19-3, and remove the pistons, operation 13-1...1482
4 Turn the engine to a vertical position with the flame face uppermost...1482
5 Extract the cylinder liners using the special tool, 21825 790. Remove and discard the sealing r...1482
6 Inspect the cylinder liners, operation 16-5...1482
1 Apply a thin smear of ‘Linalube’ to the sealing ring area at the base of each cylinder bore. En...1482
2 Apply ‘Loctite 5920’ as a bead of 2-3 mm (1/8 in) diameter (A2). Ensure that the sealant is app...1482
3 Apply a light smear of ‘Linalube’ to the sealing rings and fit them to the liner as shown (B). ...1482
4 Liners may be pressed in by hand. If difficulties are encountered it is advisable to withdraw t...1483
5 After the cylinder liners have been fitted, check the bores (B) for ovality and taper. The maxi...1483
6 Remove the clamps and fit the pistons, operation 13-1...1483
7 Fit the cylinder heads, operation 12-4...1483
8 Fit and the sump, operation 19-3. Fill the coolant and lubrication systems to the correct levels...1483
To clean and to inspect 16-5...1483
Cam followers...1484
To remove and to fit 16-6...1484
1 If a compressor is fitted to the engine, drain the coolant system to below the level of the coo...1484
2 Remove the rocker covers and the rocker assemblies, operation 12-1 and operation 12-2. Withdraw...1484
3 Where fitted, disconnect and remove the oil feed and coolant pipes from the compressor, and rem...1484
4 Slacken the hose clip and remove the breather pipe from the cam follower cover...1484
5 Remove the cam follower cover and withdraw the baffle. Discard the joints...1484
6 Lift out the cam followers. Keep the cam followers in the correct sequence to ensure that they ...1484
1 Ensure that the joint faces on the cover plate and crankcase are clean...1484
2 Lightly smear the cam followers with clean engine oil and fit them to the correct positions in ...1484
3 Fit the baffle and cover plate, complete with new joints...1484
4 Fit the breather pipe to the cover and tighten the clip...1484
5 Fit the oil feed pipe, the coolant pipes and the air supply pipe to the compressor...1484
6 Fit the push rods to the relevant cam followers. Fit the rocker assembly, operation 12-2, and a...1484
7 Fit the rocker covers, operation 12-1...1484
8 If the coolant system was drained, fill to the correct level with the approved coolant mixture...1484
Camshaft...1485
To remove and to fit - bolt-on type 16-7...1485
1 Remove the cam followers, operation 16-6...1485
2 Remove the alternator, operation 23-2...1485
3 Remove the coolant pump, operation 21-5...1485
4 Remove the crankshaft pulley assembly, operation 14-1 or operation 14-2, and the wheelcase, ope...1485
5 Turn the engine until No.1 piston is at TDC with the relevant mark on the flywheel aligned with...1485
6 Remove the five bolts from the drive gear and withdraw the gear...1485
7 Unscrew and remove the thrust plate...1485
8 Carefully withdraw the camshaft...1485
1 Lightly smear the journals and bearing surfaces with clean engine oil and carefully insert the ...1485
2 Ensure that the thrust plate bolts and their respective holes in the crankcase are clean and fr...1485
3 Fit and secure the camshaft gear (A3) to the camshaft with the timing mark aligned with the cor...1485
4 If the end float exceeds the limits it must be corrected by fitting a new thrust plate or drive...1485
5 When the end float is correct, check that the gear retaining screws are tightened to the correc...1485
6 Ensure that the timing marks on the idler gear (A1), crankshaft gear (A2) and camshaft gear (A3...1485
7 Fit the wheelcase, operation 15-1...1485
8 Fit the crankshaft pulley assembly, operation 14-1 or operation 14-2...1485
9 Fit the coolant pump, operation 21-5...1485
10 Fit the alternator, operation 23-2...1485
11 Fit the cam followers, operation 16-6...1485
Camshaft...1486
To remove and to fit - integral type 16-8...1486
1 Remove the cam followers, operation 16-6...1486
2 Remove the alternator, operation 23-2...1486
3 Remove the coolant pump, operation 21-5...1486
4 Remove the crankshaft pulley assembly, operation 14-1 or operation 14-2, and the wheelcase, ope...1486
5 Remove the idler gear...1486
6 Rotate the camshaft gear until the capscrews which retain the thrust plate can be seen through ...1486
7 Remove the thrust plate capscrews...1486
8 Carefully withdraw the camshaft...1486
1 Turn the engine until the number 1 piston is at TDC with the mark on the end of the crankshaft ...1486
2 Lightly smear the camshaft journals and bearing surfaces with clean engine oil and carefully in...1486
3 Rotate the camshaft gear until the capscrews which retain the thrust plate can be fitted throug...1486
4 Check the camshaft end float as shown (A). Limits for end float are 0,152 to 0,405 mm (0.006 to...1486
5 Fit the idler gear...1486
6 Ensure that the timing marks on the idler gear (BI), the crankshaft gear (B2) and the camshaft ...1486
7 Check the backlash between the idler gear and the camshaft gear, and also between the idler gea...1486
8 Fit the wheelcase, operation 15-1...1486
9 Fit the crankshaft pulley assembly, operation 14-1 or operation 14-2...1486
10 Fit the coolant pump, operation 21-5...1486
11 Fit the alternator, operation 23-2...1486
12 Fit the cam followers, operation 16-6...1486
To inspect 16-9...1487
1 After the camshaft has been removed from the crankcase, clean thoroughly and check for cracks. ...1487
2 Check the cams and journals for wear or damage. Small marks can be removed by the use of a smoo...1487
3 Check the thrust plates for wear or damage and renew them if necessary...1487
4 Where necessary, check the camshaft bush in the crankcase for wear or damage and renew if neces...1487
5 With the camshaft fitted in the crankcase, check the end float as given in operation 16-7 or op...1487
6 Check the backlash between the idler gear and the camshaft gear, and also between the idler gea...1487
Fits and clearances...1488
Engine timing...1490
Valve timing...1490
To check 17-1...1490
1 Remove the timing pointer cover from the flywheel housing...1490
2 Remove the rocker covers and joints...1490
3 Turn the engine forward (clockwise viewed from the front) until the valves of No. 6 cylinder ar...1490
4 Adjust the clearance of the No. 1 cylinder inlet valve to 0,89 mm (0.035 in)...1490
5 Continue turning the engine forward until a 0,13 mm (0.005 in) feeler gauge is just nipped betw...1490
6 If satisfactory, return the engine to the No. 6 cylinder valves ‘rocking’ position. If not, che...1490
1 Reset No. 1 cylinder inlet valve clearance to 0,25 mm (0.010 in) and fit the timing pointer cover...1490
2 Remove the joints from the rocker covers and clean the corresponding faces of the covers and cy...1490
Fuel injection pump timing...1491
To check and to adjust 17-2...1491
1 The injection timing position is stamped on the engine data plate...1491
2 Secure the stop lever in the NO FUEL position and remove the front rocker cover...1491
3 Turn the engine in the normal direction of rotation (anti-clockwise viewed on flywheel) until N...1491
4 Continue turning the engine until the figure on the flywheel, corresponding to that stamped on ...1491
5 Remove the cap nut from the fuel injection pump and withdraw the timing pointer location device...1491
6 Invert the location device and refit it to its original position with the location slot horizon...1491
7 If the location device does not enter fully the timing is incorrect and the access cover (A1) m...1492
8 Slacken the four gear retaining bolts (B) and turn the pump camshaft, with a 30 mm spanner, unt...1492
9 Tighten the gear retaining bolts to a torque of 45 Nm (33 lbf ft) and withdraw the location dev...1492
10 Turn the engine backwards a minimum of 60 degrees and repeat paragraphs 4, 5 and 6...1492
11 If timing is still incorrect repeat paragraphs 4 to 9 inclusive...1492
12 Proceed as follows when the timing is correct...1492
13 Fit the front access cover plate...1492
14 Withdraw the location device (C1), invert it and refit it as shown (C). The pointer location s...1492
15 Fit the rocker cover, release the engine stop lever and fit the timing pointer cover plate to ...1492
Aspiration system...1494
General description...1494
Aspiration system maintenance...1494
1 Service the air cleaner in accordance with the Perkins recommendations given in section 4 of th...1494
2 At frequent intervals inspect the induction and exhaust systems for leakage and deterioration o...1494
3 During servicing, take special care to prevent dirt and loose articles from entering the induct...1494
4 The exhaust manifolds are made from a special alloy to protect the turbocharger turbine wheel f...1494
5 At frequent intervals check that the turbocharger oil feed and drain pipes are undamaged. Restr...1494
6 Use an approved lubricating oil of the correct grade and specification and maintain the engine ...1494
7 Make periodic checks to ensure that the exhaust system is unrestricted (for example: by choked ...1494
8 If investigation of an engine fault involves checking the turbocharger, remove the trunking and...1494
9 Certain turbochargers are fitted with a waste-gate. The operation of the waste-gate must be che...1495
Turbocharger...1496
To remove and to fit 18-1...1496
1 Remove the turbocharger air ducts and the oil feed and drain pipes. Do NOT damage or bend the p...1496
2 Support the turbocharger, unscrew the four securing nuts and remove the unit...1496
1 Clean the exhaust manifold and turbocharger mating faces, position the turbocharger on the exha...1496
2 Fit the oil supply and drain pipes. Tighten the two bolts which retain the oil inlet flange to ...1496
3 Prime the turbocharger bearing housing as follows:...1496
How to check the waste-gate 18-2...1496
1 Apply air pressure up to a maximum of 207 kN/m· (30 lbf/in·) and feel for movement of the end o...1496
2 If the rod fails to move, disconnect the rod from its lever and try to move the lever by hand. ...1496
3 With the rod still disconnected, test the assembly again with air pressure upto 207 kN/m· (30 l...1496
Turbochargers: OE49342, OE50642, OE51140, and OE51430...1497
To dismantle and to assemble 18-3...1497
1 Use a scriber to mark the relative positions of the turbine housing (A23), the bearing housing ...1497
2 Clamp the unit on the turbine inlet flange in a vice in an upright position...1497
3 Remove the bolts (A4) and the clamping plates (A2) and lift off the compressor housing...1497
4 Bend back the tabs on the locking plates (A25) and remove the bolts (A24) and clamping plates (...1497
5 Use a scriber to mark the relative position of the compressor impeller (A6) to the turbine shaf...1498
6 Slide the compressor impeller (A6) off the shaft...1498
7 Ease out the retaining ring (A7), using a small screwdriver, and remove the oil seal plate (A8)...1498
8 Lift out the oil baffle (A12)...1498
9 Remove the three flat head cap screws (A14) and withdraw the thrust bearing (A15) and thrust co...1498
10 Remove the shaft assembly (A21) together with the seal (A22) and remove the heat shield (A20)...1498
11 Remove the outer retaining rings (A17), withdraw the bearings (A18), and remove the inner reta...1498
1 Ensure that the parts which have been marked for alignment purposes are fitted correctly...1498
2 Bevelled faces of the retaining rings (A17) must be assembled towards the bearings (A18)...1498
3 Lightly smear all parts with a film of clean engine oil prior to fitting...1498
4 Do not force seals (split ring) into bores as they may fracture and cause binding...1498
5 Take care not to trap or damage the ‘O’ ring seal (A9) when assembling the plate (A8) to the be...1498
6 Mount a dial test indicator gauge at the end of the shaft and check the end float of the shaft ...1498
7 Mount the dial test indicator gauge on the compressor impeller boss and check the extreme radia...1498
8 When fully assembled, check by hand that the rotor spins freely...1498
9 The following specific torques must be applied during assembly:...1498
10 Bend over the tabs of the locking plates on the turbine and compressor housings...1498
To clean and to inspect 18-4...1499
1 Use a commercially approved non-caustic cleaning solution to soak parts until all deposits have...1499
2 Clean all aluminium parts with a bristle type brush or plastic scraper. Vapour blast may be use...1499
3 Blow compressed air through all drilled passageways and ensure that the surfaces adjacent to th...1499
1 Inspect the shaft bearing journals and the walls of the seal grooves for wear and excessive scr...1499
2 Check the turbine and compressor wheels for cracked or damaged blades but do NOT attempt to str...1499
3 Check the thrust bearing surfaces for wear or damage. Minor scratches are acceptable. Ensure th...1499
4 Replace the bearings if excessively scratched or worn...1499
5 Replace the bearing housing if the bearing or seal bores are severely scratched or worn...1499
6 Have the balance of the rotor assembly checked at an establishment which has the relevant speci...1499
7 Replace the ‘O’ ring seal (A9)...1499
8 Check the turbine housing for signs of rubbing, flaking and overheating. Slight damage is accep...1499
9 Check the compressor housing for damage due to contact with the rotor. Slight damage is accepta...1499
Turbocharger: OE50674...1500
To dismantle and to assemble 18-5...1500
1 Use a scriber to mark the relative positions of the turbine housing (A23), the bearing housing ...1500
2 Clamp the unit on the turbine inlet flange in a vice in an upright position...1500
3 Slacken the ‘V’ band clamp and carefully remove the compressor housing...1500
4 Bend back the tabs on the clamping plates (A15). Remove and discard the bolts (A16) and clampin...1500
5 Check that the bearing housing and turbine assembly rotates freely in the turbine housing. If n...1500
6 Locate the turbine wheel in a 29 mm socket clamped in a vice or a suitable fixture. Use a scrib...1500
7 Slide the compressor impeller (A4) from the shaft...1500
8 Remove the assembly from the socket and carefully withdraw the turbine shaft and wheel (A22) fr...1500
9 Carefully remove the piston ring type seal (A9) from the shaft...1500
10 Remove the heat shield (A9)...1500
11 Secure the bearing housing, with the diffuser (A5) uppermost, in a vice fitted with soft jaws...1500
12 Remove the four diffuser screws and washers. If the screws are tight, use a penetrating oil to...1500
13 Remove the oil slinger (A7) from the diffuser. Remove and discard the piston ring type seal (A...1500
14 Remove and discard the oil baffle (A17)...1501
15 Remove the shim (A19)...1501
16 Remove the thrust bearing (A20) and the thrust collar (A21)...1501
17 Remove and discard the ‘O’ ring seal (A18)...1501
18 Use circlip pliers to remove the two circlips (A14) and the journal bearing (A13) from the com...1501
19 Turn the bearing housing over. Remove and discard the two circlips (A11) and the journal beari...1501
1 Place the turbine housing on a flat bench with the turbine end uppermost. Fit the circlip with ...1501
2 Lubricate the journal bearing and fit it into the bearing housing. Fit the second circlip with ...1501
3 Turn the turbine housing over and repeat the procedure with the other journal bearing and circl...1501
4 Fit the heat shield...1501
5 Fit a new piston ring seal to the turbine shaft...1501
6 Use clean engine oil to lubricate the turbine shaft, then enter the shaft into the bearing hous...1501
7 Support the assembly in a suitable fixture and use pliers to pull out the two roll pins by appr...1501
8 Fit the thrust collar. Ensure that the balance mark on the thrust collar is aligned with that o...1501
9 Apply a light coat of engine oil to the thrust bearing and fit it to the bearing housing...1501
10 Fit a new shim. It must be fitted with the letter ‘T’ facing away from the thrust bearing...1501
11 Fit the oil baffle into the housing...1501
12 Fit a new piston ring to the oil slinger. Apply a light coat of engine oil to the slinger and ...1501
13 Lubricate and install the ‘O’ ring seal...1501
14 Align the balance marks on the oil slinger with that on the end of the shaft and fit the diffu...1501
15 Fit four new diffuser bolts and washers. Tighten the diffuser bolts in a diagonal pattern to a...1501
16 Align the balance marks and fit the compressor wheel onto the shaft. Fit the compressor wheel ...1501
17 Secure the turbine housing in a vice or suitable fixture. Fit the bearing housing assembly to ...1501
18 Position a dial test indicator so that its plunger is resting on the end of the shaft. Check t...1501
19 Mount the dial test indicator gauge with its plunger resting on the side of the shaft above th...1501
20 Loosely fit the ‘V’ band clamp and fit the compressor housing...1502
21 Align the scribe marks and tighten the ‘V’ band clamp to a torque of 8,5 Nm (75 lbf in) and be...1502
To clean and to inspect 18-6...1502
1 Use a commercially approved non-caustic cleaning solution to soak parts until all deposits have...1502
2 Clean all aluminium parts with a bristle type brush or plastic scraper. Vapour blast may be use...1502
3 Blow compressed air through all drilled passageways and ensure that the surfaces adjacent to th...1502
1 Inspect the shaft bearing journals and the walls of the seal grooves for wear and excessive scr...1502
2 Check the turbine and compressor wheels for cracked or damaged blades but do NOT attempt to str...1502
3 Place the turbine shaft (A22) on a vee block with a dial test indicator positioned at the oppos...1502
4 Inspect the journals of the turbine shaft for excessive scratches and wear. Minor scratches are...1502
5 Check the thrust bearing surfaces for wear or damage. Minor scratches are acceptable. Ensure th...1502
6 Renew the bearing housing (A12) if the bearing or seal bores are severely scratched or worn. En...1502
7 Check the profile in the turbine housing for damage caused by possible contact with the rotor. ...1502
8 Check the compressor housing for damage caused by possible contact with the rotor. Slight damag...1502
9 Inspect the oil slinger (A7). Ensure that the walls of the seal grooves are not scored or damag...1502
10 Inspect the seal bore of the diffuser (A5), renew if scored or damaged...1502
11 Inspect the heat shield (A9), renew if there are signs of distortion, rubbing or cracks...1502
Turbochargers: OE52534 and OE52535...1503
To dismantle and to assemble 18-7...1503
1 Use a scriber to mark the relative positions of the turbine housing (A26), the bearing housing ...1503
2 Clamp the unit on the turbine inlet flange in a vice in an upright position...1503
3 Remove, if fitted, the retaining ring (A1) and baffle plate (A2)...1503
4 Remove, if fitted, the two nuts which retain the cylinder of the waste-gate assembly. Make a no...1503
5 Remove the eight bolts and the clamping plates (A5) and lift off the compressor housing. If fit...1503
6 Bend back the tabs on the clamping plates (A25) and remove the bolts (A24) and clamping plates ...1503
7 Locate the turbine wheel in a 19 mm socket clamped in a vice or a suitable fixture. Use a scrib...1503
8 Slide the compressor impeller (A7) from the shaft...1503
9 Remove the assembly from the socket and carefully withdraw the turbine shaft and wheel (A23) fr...1503
10 Carefully remove the two piston ring type seals (A22) from the shaft...1503
11 Remove the heat shield (A21)...1503
12 Using circlip pliers, remove the insert retaining ring (A8)...1503
13 Use two flat screwdrivers to gently remove the oil seal plate (A9)...1504
14 Remove the oil slinger (A12) and and remove and discard its piston ring seal (A11)...1504
15 Remove and discard the ‘O’ ring seal (A10)...1504
16 Remove the oil baffle (A13)...1504
17 Remove the thrust bearing (A14) and the thrust collar (A15)...1504
18 Remove and discard the two circlips (A16) and withdraw the journal bearing (A17)...1504
19 Turn the bearing housing over. Remove and discard the two circlips (A19) and withdraw the jour...1504
1 Place the turbine housing on a flat bench with the turbine end uppermost. Fit the circlip with ...1504
2 Lubricate the journal bearing and fit it into the bearing housing. Fit the second circlip with ...1504
3 Turn the turbine housing over and repeat the procedure with the other journal bearing and circl...1504
4 Fit the heat shield...1504
5 Fit new piston ring seals (A22) to the turbine shaft. Fit them with their gaps 180 degrees apar...1504
6 Lubricate the turbine shaft and fit it into the bearing housing...1504
7 Support the assembly in a suitable fixture and fit the thrust collar. Ensure that the balance m...1504
8 Apply a light coat of engine oil to the thrust bearing and fit it to the bearing housing...1504
9 Apply a small amount of clean engine oil to the ‘O’ ring seal and fit it into the housing...1504
10 Fit the oil baffle into the housing...1504
11 Fit a new piston ring to the oil slinger and insert it into the oil seal plate...1504
12 Fit the oil seal plate into the bearing housing. Ensure that the balance marks on the oil slin...1504
13 Use circlip pliers to fit the circlip...1504
14 Align the balance marks and fit the compressor wheel onto the shaft. Fit the compressor wheel ...1504
15 Secure the turbine housing in a vice or suitable fixture. Fit the bearing housing assembly to ...1504
16 Position a dial test indicator so that its plunger is resting on the end of the shaft. Check t...1504
17 Mount the dial test indicator gauge with its plunger resting on the side of the shaft above th...1504
18 If fitted, install the ‘O’ ring seal...1504
19 Fit the compressor housing and align the scribe marks. Take care not to damage the compressor ...1505
20 When fully assembled, check by hand that the rotor spins freely...1505
21 Bend over the tabs of the locking plates on the turbine and compressor housings...1505
22 Where necessary, fit the inlet baffle and its retaining ring to the compressor housing...1505
To clean and to inspect 18-8...1505
1 Use a commercially approved non-caustic cleaning solution to soak parts until all deposits have...1505
2 Clean all aluminium parts with a bristle type brush or plastic scraper. Vapour blast may be use...1505
3 Blow compressed air through all drilled passageways and ensure that the surfaces adjacent to th...1505
1 Inspect the shaft bearing journals and the walls of the seal grooves for wear and excessive scr...1505
2 Check the turbine and compressor wheels for cracked or damaged blades but do NOT attempt to str...1505
3 Check the thrust bearing surfaces for wear or damage. Minor scratches are acceptable. Ensure th...1505
4 Replace the bearings if excessively scratched or worn...1505
5 Renew the bearing housing if the bearing or seal bores are severely scratched or worn. Ensure t...1505
6 Check the profile in the turbine housing for damage caused by possible contact with the rotor. ...1505
7 Check the compressor housing for damage caused by possible contact with the rotor. Slight damag...1505
8 Inspect the oil slinger (A12). Ensure that the walls of the seal grooves are not scored or dama...1505
9 Inspect the bore of the oil seal plate (A9), renew if scored or damaged...1505
10 Inspect the heat shield (A21), renew if there are signs of distortion, rubbing or cracks...1505
Inlet manifold...1506
To remove and to fit 18-9...1506
1 Drain the engine coolant...1506
2 Disconnect and remove the coolant pipes from both ends of the charge cooler casing...1506
3 Remove the bolts securing the air intake pipe to the manifold. Discard the gasket...1506
4 Where necessary, remove the compressor air intake filter...1506
5 Remove the bolts and washers which secure the manifold to the cylinder heads. Remove the manifo...1506
1 Renew all gaskets and ensure that all joint faces are clean and undamaged...1506
2 Fit and secure the manifold to the cylinder heads with the relevant bolts and washers. Tighten ...1506
3 Fit the air intake pipe to the manifold, renew the gasket and tighten the bolts securely...1506
4 If relevant, fit the compressor air intake filter...1506
5 Fit the coolant pipes to the charge cooler casing...1506
6 Refill the coolant system with the recommended coolant mixture...1506
Exhaust manifold...1506
To remove and to fit 18-10...1506
1 Remove the boost control pipe from between the fuel injection pump and the air intake pipe...1506
2 Disconnect the air intake pipe from the turbocharger and remove it from the engine...1506
3 Disconnect the oil feed and drain pipes from the turbocharger...1506
4 Remove the bolts and clamps securing the manifold to the cylinder heads, and withdraw the assem...1506
5 If necessary, separate the turbocharger from the manifold...1506
1 Always use new gaskets and ensure that all joint faces are clean...1506
2 Fit and secure the manifold to the cylinder heads with the relevant bolts, washers and plates...1506
3 Tighten the bolts evenly to a torque of 45 Nm (33 lbf ft)...1506
4 Fit the turbocharger to the manifold if it was separated on removal...1506
5 Fit the air intake pipe...1506
6 Fit the boost control pipe...1506
Lubrication system...1508
General description...1508
1 Suction filter...1509
2 Pressure pump...1509
3 Oil pressure relief valve...1509
4 Oil cooler...1509
5 Parallel-flow main filters...1509
6 Piston cooling jets...1509
7 Supply to turbocharger...1509
8 Supply to injection pump (early engines)...1509
9 Idler gear axle...1509
Lubricating oil filter...1511
To renew the canister 19-1...1511
1 Put a tray under the canisters and use a strap wrench, 21825 825, to remove each canister (A1)...1511
2 Check that the sealing rings are correctly fitted to the new canisters and clean the contact fa...1511
3 Fill the two new canisters with new engine lubricating oil of the correct grade and lubricate t...1511
4 To install the new canisters use this procedure: Tighten the canisters, on their adaptors, unti...1511
By-pass filter/separator...1512
To renew the canisters 19-2...1512
1 Clean the area around the by-pass filter. Remove the filter bowl (A2), remove and discard the r...1512
2 Remove the seal (A4) from the filter bowl and clean all the components, especially the recess f...1512
3 Fit a new seal to the recess in the filter bowl and lubricate the face of the seal with clean e...1512
4 Fit a new rotor to the spindle and ensure that it can rotate freely. Fit the filter bowl and ti...1512
5 When the engine is operated, check for leakage from the by-pass filter...1512
Sump...1513
To remove and to fit 19-3...1513
1 Drain the engine lubricating oil into a suitable clean container. Refit the sump drain plug, re...1513
2 If fitted, remove the sump noise shield...1513
3 Disconnect the oil filler tube and the dipstick assembly from the sump. This is not applicable ...1513
4 Remove the oil feed pipe and elbow connection from between the sump and the crankcase. This is ...1513
5 Remove the sump bolts and, where necessary, the brackets and spacers, and remove the sump...1513
6 Discard all gaskets and ‘O’ rings...1513
1 Clean all joint faces. Renew all gaskets and ‘O’ rings...1513
2 Fit a new sump gasket to the crankcase face. For new 2000 series engines, fit a new flexible se...1513
3 Carefully place the sump in position, taking care not to disturb the gasket. If necessary use g...1513
4 Fit the relevant brackets and spacers. Fit the retaining bolts and tighten evenly to a torque o...1513
5 Fit the lubricating oil feed pipe and elbow connection between the oil cooler and the crankcase...1513
6 Fit the oil filler tube, complete with a new gasket, and fit the dipstick assembly. This is not...1513
7 Replenish the sump to the correct level with the correct grade of engine lubricating oil...1513
Sump drain plugs...1514
Lubricating oil pump...1515
To remove and to fit 19-4...1515
1 Drain the engine oil and remove the sump, operation 19-3...1515
2 Remove the oil strainer and pipework...1515
3 Unscrew the bolts securing the pump to the main bearing cap and remove the unit...1515
4 Retain any shims fitted between the pump and the bearing cap...1515
1 Fit the pump to the bearing cap, using the original shims (A2) where relevant. Ensure that the ...1515
2 The gear backlash must be between 0,010 and 0,025 mm (0.004 and 0.010 in) and is adjusted by va...1515
3 Fit the oil strainer and pipework; use new ‘O’ rings...1515
4 Fit the sump, operation 19-3, and replenish with oil...1515
To dismantle and to assemble 19-5...1516
1 Withdraw the drive gear (A1) using puller, 21825 837 (A2), with bolts (2 off), 21825 838...1516
2 Unscrew and remove the pump casing bolts and dismantle the unit...1516
1 Lightly oil all the moving parts whilst ensuring the casing joint faces remain dry and clean...1516
2 Jointing compound must NOT be used on these faces during assembly...1516
3 Assemble the pump in the sequence illustrated on page 124 (A). Drive gear end float limits are ...1516
4 Before tightening the casing bolts, check using a straight edge, that the pump mounting faces a...1516
5 Heat the drive gear to 150C (302F) and press it on until flush with the end of the shaft...1516
6 Allow to cool, fit the puller, 21825 837, and tighten the centre bolt to a torque of 20 Nm (15 ...1516
7 Remove the puller and check that the gear has remained flush with the end of the shaft...1516
8 If movement is evident the shaft and gear must be checked for wear and renewed as necessary...1516
To inspect 19-6...1516
1 Clean all components and inspect the gears, casings, and bearings for signs of wear or damage...1516
2 Carefully stone any small burrs and polish out any slight scoring...1516
3 If possible, crack test all gears...1516
Oil pressure relief valve...1517
To dismantle and to assemble 19-7...1517
1 Unscrew the cap nut and withdraw the spring and plunger...1517
1 Lightly oil the spring and plunger before sliding into position...1517
2 Fit a new washer (A3) under the cap nut and tighten securely...1517
To inspect 19-8...1517
1 Examine the plunger and the bore in the casing for wear or scoring...1517
2 Check that the plunger is a close slide fit within the bore...1517
3 Slight burrs may be stoned away, but if the wear is excessive the parts must be renewed...1517
4 Inspect the spring for wear and distortion and check that it conforms to the following dimensions:...1517
5 Renew the spring if there is any doubt regarding its serviceability...1517
Fuel system...1518
General description...1519
Overhaul instructions...1519
1 Priming plunger...1519
2 Fuel feed pump...1519
3 Fuel filter canister...1519
4 Relief valve...1519
5 Fuel injector...1519
6 Spill return to supply tank...1519
7 Lubricating oil...1519
Fuel injectors...1520
To remove and to fit 20-1...1520
1 Clean the area around the fuel injector and around its connections...1520
2 Disconnect and remove the leak-off pipe assembly from the fuel injectors...1520
3 Disconnect and remove the relevant high pressure fuel pipe. For new 2000 series engines, remove...1520
4 Remove the nuts (bolts for early engines) and the clamp which retains the relevant fuel injecto...1520
5 To remove a tight fuel injector, use the removal tool, 21825 914. Place the cylindrical portion...1520
1 Ensure that the fuel injector sleeve is clean and is free from carbon deposits...1521
2 Fit a new rubber seal (A1) onto the body of the fuel injector and a new copper sealing washer (...1521
3 Apply evenly anti-seize compound (‘Morris K72’, ‘Copaslip’ or equivalent) to the body of the fu...1521
4 If fitted, remove the plastic protection caps from the fuel injector. Fit the fuel injector int...1521
5 Fit the set of the high pressure fuel pipes. Ensure that there is no tension on the connections...1521
6 Fit and tighten all clamps which have been removed...1521
7 Fit the leak-off pipe, complete with new washers, and eliminate air from the fuel system, opera...1521
8 Run the engine and check for leakage...1521
To dismantle and to assemble 20-2...1522
1 Lightly grip the injector body in a vice and unscrew the nozzle cap nut...1522
2 Withdraw the nozzle assembly, transfer block spring cap, valve spring and adjusting shims...1522
3 Keep all the components from each injector together in individual trays...1522
1 Lightly secure the injector body (A1) in a vice...1522
2 Insert the adjusting shims (A2), valve spring (A3) and spring seat (A4). Locate the transfer bl...1522
3 Immerse the valve (A6) and nozzle (A7) in clean test oil and slide the valve fully home. Locate...1522
To clean and to inspect 20-3...1522
1 Wash the components of each injector in paraffin or fuel oil and dry with a jet of dry compress...1522
2 Soak the nozzle in a carbon solvent and remove any remaining carbon using the relevant cleaning...1522
3 It is important that the correct size of wire is used to clean the spray holes. Fit the wire in...1522
4 When the spray holes are cleared, re-soak each nozzle in carbon solvent, rinse in clean water a...1522
5 Blow through in reverse flow direction to remove any remaining loose particles...1523
1 Use a magnifying glass to inspect each valve and nozzle for damaged or worn seats and spray hol...1523
2 Dip the needle valve in clean test oil and insert it fully into the nozzle bore, held in a near...1523
3 Withdraw the valve by approximately one third of its travel. When released the valve should sli...1523
4 Inspect the pressure faces between the injector body, transfer block and nozzle for signs of sc...1523
5 Check the shims for damage and inspect the springs for distortion...1523
To set and to test 20-4...1524
1 Slacken the vent screw and operate the hand pump until bubble-free test oil emerges. Tighten th...1524
2 Connect the discharge connection to the injector inlet and tighten securely. Close the pressure...1524
Fuel lift pumps...1526
Single acting type...1526
To remove and to fit 20-5...1526
1 Clean the area immediately surrounding the feed pump...1526
2 Disconnect the fuel pipes and remove the securing nuts and washers...1526
3 Remove the lift pump from its mounting...1526
1 Refitting is a reversal of the removal procedure; use a new gasket...1526
To dismantle and to assemble 20-6...1526
1 Withdraw the sliding tappet (A1)...1526
2 Unscrew and remove the hand primer (A4)...1526
3 Carefully unscrew the roller-tappet shell (A2) and extract the plunger (A3), non-return valve (...1526
4 Clean all parts and carefully inspect for wear or damage...1526
1 Apply a light coat of clean engine oil to all parts...1526
2 Assemble the pump in the sequence as shown (A)...1526
3 Firmly secure the roller-tappet shell and the hand primer...1526
4 Sealing rings and any parts which are worn or damaged must be renewed...1526
5 Test the pump as given in operation 20-9...1526
Double acting type...1527
To remove and to fit 20-7...1527
1 Before removing the lift pump from its mounting, slacken each of the banking plugs over the thr...1527
1 Refitting is a reversal of the removal procedure; use a new gasket...1527
To dismantle and to assemble 20-8...1527
1 Remove the priming pump, plugs, valve springs, valves and pump plunger. Check all components fo...1527
1 Remove the circlip (A3) from the pump body and withdraw the roller/tappet assembly. Dismantle t...1527
2 Check the action of the hand priming pump and replace as a unit if found to be unserviceable...1527
1 Apply a light coat of clean engine oil to all components and assemble the pump using new joint ...1527
2 Test the pump as given in operation 20-9...1527
To test 20-9...1528
1 Perform a leakage test by blanking off the delivery connection and applying air pressure at 193...1528
Fuel injection pump...1529
To remove and to fit 20-10...1529
1 Disconnect and remove all relevant pipework and linkages. Do NOT bend the pipes...1529
2 Remove the front rocker cover and turn the engine in the correct direction of rotation until No...1529
3 Remove the fuel injection pump access cover (A1) from the front of the engine...1529
4 Remove the four bolts which retain the pump drive gear together with the clamping plate and wit...1529
5 Remove the four nuts and washers from the pump flange (B1) and the two nuts, bolts and washers ...1529
6 Carefully ease the pump towards the rear of the engine to remove...1529
7 If a new or reconditioned fuel injection pump is to be fitted, remove the hub from the pump...1529
1 Turn the engine in the correct direction of rotation until the No.1 inlet valve closes...1529
2 Remove the timing pointer cover (C1) from the flywheel housing...1529
3 Continue turning the engine until the timing figure on the flywheel (corresponding to the injec...1529
4 If a replacement pump is being fitted, or if the drive hub has been removed, fit the hub and ti...1529
5 Fit new ‘O’ rings; apply a light smear of ‘Linalube’ to the larger ring (A1)...1530
6 Fit the fuel injection pump onto the four studs in the rear of the wheelcase adaptor and retain...1530
7 Slacken the bolts (B1) which retain the pump support bracket. Do NOT disturb the bolts which se...1530
8 Tighten the four nuts, which secure the pump to the wheelcase adaptor, to a torque of 47 Nm (35...1530
9 Fit and tighten the rear mounting bolts to a torque of 40 Nm (30 lbf ft)...1530
10 Tighten the bolts (B1) which retain the pump support bracket...1530
11 Remove the cap nut and withdraw the timing pointer location device (C1)...1530
12 Turn the pump camshaft, using a 30 mm spanner, until the timing pointer is visible in the cent...1530
13 Fit the pump drive gear. Ensure that the hub bolt holes are positioned centrally within the sl...1530
14 Fasten the stop lever in the NO FUEL position...1530
15 Ensure that the timing pointer is still positioned in the centre of the aperture and insert th...1530
16 If necessary turn the pump camshaft, using a 30 mm spanner, until the location device (D1) ent...1530
17 Tighten the pump drive gear securing bolts to a torque of 45 Nm (33 lbf ft)...1530
18 Withdraw the location device...1530
19 Turn the engine backwards by at least 60 degrees and repeat the timing check. Proceed when the...1530
20 Fit the front access cover plate...1530
21 Insert the timing pointer location device with the location slot outwards and refit the cap nut...1531
22 Fit the front rocker cover and fit the timing pointer cover plate to the flywheel housing...1531
23 Fit all the relevant pipework. Do NOT bend the pipes. The high pressure fuel pipes of new 2000...1531
24 Release the stop lever to the RUN position...1531
How to eliminate air from the fuel system 20-11...1532
1 Ensure that there is fuel in the operating tank and that all leakages have been eliminated...1532
2 Loosen the union at the outlet pipe from the lift pump; operate the hand priming pump (A1) and ...1532
3 Continue to operate the hand priming pump and loosen the union on the outlet side of the fuel f...1532
4 Continue to operate the hand priming pump and loosen in turn, each union where the high pressur...1532
5 With all unions tightened, continue to hand prime until the relief valve is heard to open...1532
6 Wipe away all spilt fuel...1532
Air stop cylinder...1533
How to set the air-operated stop cylinder 20-12...1533
1 Ensure that all the nuts and bolts which attach the air cylinder and the mounting bracket to th...1533
2 Ensure that the air system of the vehicle is fully charged...1533
3 Rotate the outer stop lever in a clockwise direction until it is tight against its fixed stop s...1533
4 Energise the air cylinder (A1 or B1)...1533
5 While the outer stop lever is still held against the outer stop screw, slacken the lock nut and...1533
6 De-energise the stop cylinder. Energise the stop cylinder and check that there is 1mm (0.039 in...1533
Cooling system...1534
General description...1534
1 Oil cooler...1535
2 Coolant inlet gallery...1535
3 Charge cooler...1535
4 Coolant rail...1535
5 Coolant outlet to radiator...1535
6 Thermostat housing...1535
7 Thermostat...1535
8 To thermostat from outlet gallery...1535
9 Thermostat by-pass to coolant pump...1535
10 Coolant pump to inlet gallery...1535
11 To coolant pump from oil cooler...1535
12 Drain plugs...1535
13 To engine from radiator...1535
14 To radiator from engine...1535
1 Oil cooler...1536
2 Coolant inlet gallery...1536
3 Air inlet manifold...1536
4 Coolant outlet gallery...1536
5 Coolant outlet to radiator...1536
6 Thermostat housing...1536
7 Thermostat...1536
8 To thermostat...1536
9 Radiator by-pass system...1536
10 Coolant pump to inlet gallery...1536
11 To coolant pump from oil cooler...1536
12 Coolant pump...1536
13 To engine from radiator...1536
14 Drain plugs...1536
15 Air-to-air charge cooler...1536
16 Fan...1536
Radiator...1537
To remove and to fit 21-1...1537
1 Drain the coolant system as given in the User's Handbook TSD3215...1537
2 Disconnect and remove the pipe from between the oil cooler and the radiator...1537
3 Disconnect and remove the pipe (B1) from between the thermostat housing and the radiator...1537
4 Release the hose clips at the radiator end of the turbocharger-to-radiator air duct...1537
5 Remove the air duct (B2), and retaining straps, from between the connection on the inlet manifo...1537
6 Remove the nuts and bolts which secure the radiator to the radiator stand and carefully slide t...1537
1 Place the radiator on the radiator stand and carefully slide it toward the engine until the fan...1537
2 Loosely fit the nuts, bolts and washers which retain the radiator on the radiator stand...1537
3 Rotate the fan so that two of the fan blades are horizontal. Stand behind the engine and check ...1537
4 Rotate the fan until two of the fan blades are vertical. Check the distance between the radiato...1537
5 Fit the air duct (B2) between the inlet manifold and the radiator, but do not tighten the hose ...1537
6 View the radiator and fan from the side to check the angle of the radiator to the engine. Check...1537
7 Fit the coolant pipe (A1) between the thermostat housing and the radiator. Use new hoses and ti...1538
8 Fit the coolant pipe between the oil cooler and the radiator. Use new hoses and tighten the hos...1538
9 Using a new hose, connect the air duct from the turbocharger to the radiator. Tighten the hose ...1538
10 Fit the air duct assembly between the turbocharger and the radiator, use new hoses but do not ...1538
11 Fit the guards. Ensure that they are not in contact with any part of the engine except where t...1538
12 Fill the radiator with the correct coolant specification...1538
Fan...1538
To remove and to fit 21-2...1538
1 Remove the radiator, operation 21-1...1538
2 Remove the six retaining screws, remove the fan and collect the spacer if fitted...1538
1 Where necessary, fit the spacer. Fit the fan and retain with six bolts and spring washers. Tigh...1538
2 Check that the spring washers have seated correctly and have not spread out. If any have become...1538
3 Fit the radiator, operation 21-1...1538
Fan drive belts...1539
How to check the fan belts 21-3...1539
How to adjust the tension of the fan belts 21-4...1539
Coolant pump...1540
To remove and to fit 21-5...1540
1 Drain the coolant system...1540
2 Remove the radiator, operation 21-1...1540
3 Remove the cooling fan, operation 21-2...1540
4 Remove the alternator and drive belt/s...1540
5 Release the belt tension and remove the coolant pump drive belts...1540
6 Remove the coolant pump drive pulley. For engines with low mounted pump, remove the crankshaft ...1540
7 Slacken the hose clips and disconnect the coolant pipe from the coolant pump...1540
8 Unscrew the pump retaining bolts and remove the pump...1540
1 Ensure that all joint surfaces are clean...1540
2 Fit the pump, complete with new joints...1540
3 Fit the crankshaft pulley, and damper if applicable...1540
4 Fit the coolant pump pulley and tighten the securing bolts to a torque of 24 Nm (18 lbf ft)...1540
5 Fit the coolant pump drive belts...1540
6 Fit the mounting bracket and, where applicable, the alternator and its drive belt/s...1540
7 Adjust the tension of all belts, operation 21-4 and operation 23-1...1540
8 Connect the coolant pipe between the oil cooler and the coolant pump...1540
9 Fit the fan, operation 21-2...1540
10 Fit the radiator, operation 21-1...1540
11 Refill the coolant system with the correct coolant mixture...1540
To dismantle and to assemble 21-6...1541
1 Remove the pump backplate, where applicable...1541
2 Withdraw the impeller (A5) from the shaft using the puller, 21825 837, and two bolts, 21825 838...1541
3 Position the pump assembly on a press and remove the shaft (A4) by pressing it out towards the ...1541
4 Remove the hub (A14), lever out the front oil seal (A13) and release the circlip (A12)...1541
5 Lever out the ‘balanced’ seal (A1) and the ceramic counterface (A6)...1541
1 Pack the bearing with Shell Retinax ‘A’ grease. The later type of bearing is ‘double-sealed’ an...1542
2 Ensure that the outer diameter of the bearing and the inner diameter of the bearing housing are...1542
3 Use a brush to apply a coat of ‘Loctite 648’ to the shoulder inside the bearing housing (A)...1542
4 Press the bearing into the housing using the special tool, 21825 904, with the sealed side of t...1542
5 Apply grease to the inside of the bearing housing and insert the two spacers...1542
6 Add a further smear of grease to the housing and press in the outer cone of the roller bearing...1542
7 Use a degreasing fluid to clean the shaft. The shaft MUST be free from oil and grease. Apply a ...1542
8 Support the front end of the pump on the bearing replacer, 21825 904, and press in the shaft to...1542
9 Press in the ‘balanced’ seal over the shaft, using tool, 21825 899, (C1)...1542
10 Fit a new ceramic counterface seal into the impeller. Do NOT touch the sealing face of the cer...1542
11 Support the pump under a press and press the impeller onto the shaft until the front face of t...1542
12 Press a new oil seal into the front of the pump, using special tool, 21825 903, with the open ...1542
13 Heat the hub in an oven to a temperature of 130C (226F), or alternatively, immerse it in con...1543
14 Place the pump on the press with the lower end of the shaft fully supported...1543
15 Remove the hub from the heating process and, while it is still hot, press it onto the shaft fi...1543
16 It is now necessary to check the hub for tightness on the shaft. Before doing so, the pump mus...1543
17 Fit a puller, 21825 837, to the pump hub (A) and tighten the centre bolt to a torque of 27 Nm ...1543
To inspect 21-7...1544
1 Inspect all of the components for damage or corrosion...1544
2 Discard all seals and joints...1544
3 Measure the diameter of the shaft (A4) and the bore of the hub (A14). The interference fit shou...1544
4 Clean and check the bearings (A8 and A11) for wear or damage. Spin the ball bearing by hand to ...1544
Thermostat...1545
How to check the operating temperatures 21-8...1545
1 Mark the strap of the leading valve and place the thermostat, the correct way up, in a containe...1545
2 Heat the water, and note the temperature at which the leading valve opens sufficiently to admit...1545
3 Continue heating and note the opening temperature of the two trailing valves...1545
4 Continue heating, noting the temperature at which each valve stops moving and is fully open, i...1545
5 Compare the readings with the following limits:...1545
How to check the operating speed 21-9...1546
1 Immerse the thermostat, with all the valves fully closed, in boiling water to the level of the ...1546
2 Maintain the water at boiling point and note the time taken, from immersion, for all valves to ...1546
3 Remove the thermostat and plunge it into cold water, noting the time taken for all valves to cl...1546
4 Compare the readings taken with the following limits:...1546
5 Should a thermostat fail to operate satisfactorily within the given limits it must be replaced...1546
Oil cooler...1547
To dismantle and to assemble 21-10...1547
1 Drain the coolant and disconnect the coolant hoses and lubricating oil pipes from the unit...1547
2 Remove the two canister type oil filters...1547
3 Remove the bolts which secure the unit to the mounting and lift it away...1547
4 Unscrew the 2BA screw (A3) from each end of the housing. Push the tube pack forward enough to a...1547
5 Withdraw the tube carefully towards the rear. Do NOT attempt to push the pack through the housi...1547
6 Wash the pack carefully in fuel oil, blow through the tubes with compressed air and wash in hot...1547
7 Blocked tubes may be cleared by soaking the pack in a solution of 1 part inhibited hydrochloric...1547
1 Refer to paragraph 5 on page 156 with regard to the use of pressure on the tube pack. Always re...1548
2 Apply a light smear of rubber grease or ‘Linalube’ to both ends of the housing bore...1548
3 Insert the tube pack into the housing, with the machined recesses aligned for the locating scre...1548
4 Fit a new lightly lubricated ‘O’ ring. Pull the tube backwards until the rear ‘O’ ring groove i...1548
5 Fit a lightly lubricated ‘O’ ring and push the pack back into the housing to its correct position...1548
6 Align the pack and fit the locating screws, complete with washers, to each end...1548
7 Fit the unit to the engine with the relevant screws and washers...1548
8 Connect the oil pipes and coolant pipes and refill the coolant system to the correct level...1548
9 Fit new filter canisters: check that the sealing rings are correctly fitted to the new canister...1548
10 Fill the two new canisters with new engine lubricating oil of the correct grade and lubricate ...1548
11 To install the new canisters use this procedure: Tighten the canisters, on their adaptors, unt...1548
To inspect 21-11...1548
1 Visually inspect the pack for signs of cracks, corrosion or obvious damage...1548
2 If possible, pressure test by applying air to the tube bores at 207 kN/m· (30 lbf/in·) pressure...1548
3 Ensure that the housing is clean and completely free from burrs...1548
Flywheel and flywheel housing...1550
General description...1550
Flywheel...1552
To remove and to fit 22-1...1552
1 Remove the timing pointer from the flywheel housing to prevent it from fouling the ring gear wh...1552
2 Remove two horizontally opposed flywheel retaining bolts and replace with two guide studs, 2182...1552
3 Unscrew and remove the remaining ten bolts...1552
4 Carefully release the flywheel from its dowel and slide it onto the guide studs. Fit the liftin...1552
1 Ensure that the two guide studs, 21825 802, are fitted securely...1552
2 Lift the flywheel onto the guide studs and align the dowel hole with the dowel in the crankshaft...1552
3 Fit the securing bolts and washers and remove the guide studs. Tighten the bolts evenly to a to...1552
4 Fit the timing pointer and its cover...1552
To inspect 22-2...1552
1 Examine the flywheel for cracks or damage and replace if necessary...1552
2 Inspect the ring gear for cracks or wear and if necessary, renew as follows:...1552
a Drill holes in the ring gear body at diametrically opposite positions until it is weakened suff...1552
b Remove any burrs from the flywheel ring gear and the seating area on the flywheel...1552
c Heat the new ring gear to approximately 215C (419F), fit it to the flywheel and rotate it to ...1552
d Allow it to cool naturally, and then check with a feeler gauge that it is fully against the sho...1552
3 Examine the flywheel friction plate for wear, scoring or cracks and renew if necessary...1552
Flywheel housing...1553
To remove and to fit 22-3...1553
1 Remove the flywheel, operation 22-1...1553
2 Remove the starter motor, operation 23-3...1553
3 Remove the bolts which secure the housing to the crankcase...1553
4 Using suitable lifting equipment, release the housing from its dowels and remove...1553
1 Ensure that both joint surfaces are free from burrs and damage...1553
2 Fit the flywheel housing as follows:...1553
3 Lift the housing onto the locating dowels and fit the retaining bolts and washers. Tighten the ...1553
4 Fit the flywheel, operation 22-1...1553
5 Fit the starter motor, operation 23-3...1553
Electrical equipment...1554
General description...1554
Alternator drive belts...1556
To check and to adjust the tension 23-1...1556
Alternator...1557
To remove and to fit 23-2...1557
1 Disconnect the battery...1557
2 Slacken the adjustment bolt (A1) and pivot bolt (A2), and remove the alternator drive belt (A3)...1557
3 Disconnect the wiring loom from the alternator. Make a note of the position of the connectors t...1557
4 Remove the adjustment bolt, nut and washers. Remove the pivot bolt and lift away the alternator...1557
1 Fit the alternator. Retain with the pivot bolt and a spring washer. Then fit the adjustment bol...1557
2 Reconnect the wiring loom to the alternator...1557
3 Fit the alternator drive belt and adjust the tension, operation 23-1...1557
4 Connect the battery...1557
Starter motor...1558
To remove and to fit 23-3...1558
1 Disconnect the battery...1558
2 Make a note of the terminals of the starter motor assembly and of the cables which are connecte...1558
3 Disconnect the cables from the starter motor assembly...1558
4 Remove the three screws and plain and spring washers and carefully withdraw the starter motor a...1558
1 Fit carefully the starter motor assembly to the flywheel housing, fit the three retaining screw...1558
2 Connect the cables to the correct terminals...1558
3 Connect the battery...1558
To dismantle and to assemble the solenoid switch 23-4...1558
1 Remove both jumper leads from between the solenoid switch and the starter body...1558
2 Extract the rubber plug from the solenoid base, insert the special tool, engage it with the tim...1558
3 Remove the lock nuts, the washers and the sealing rings from both of the small terminals; parti...1558
4 Hold the protrusion of the plunger (A2) at the opposite end of the body (A9) and release the nu...1559
1 Assemble the shaft (A1) and the plunger (A2), if they have been separated, and fit the spring t...1559
2 Fit the shaft through the body (A9) of the solenoid switch and fit the washer, the insulation w...1559
3 Fit the terminal insulators. Fit the cover to the body sufficient for the small screw (A6) to b...1559
4 Fit a new rubber shroud to the housing of the shift lever and ensure that the lip is engaged fu...1559
5 Align the screw link with the threaded hole in the plunger (A2) and insert the special tool thr...1559
6 Fit the two bolts which secure the solenoid switch to the starter motor and tighten them to 34,...1559
7 DO NOT fit the flexible cable and the copper connector until solenoid adjustment is completed i...1559
To dismantle and to assemble the starter motor 23-5...1560
1 Remove the solenoid switch, operation 23-4...1560
2 Remove the cover (A4), release the connections and carefully withdraw the carbon brushes (A3)...1560
3 Disconnect the two cables from the field windings (A7), release the four bolts and remove the e...1560
4 Release the six cap screws and remove the pinion housing (A8); disconnect and remove the pinion...1560
5 Remove the screw and washer from the housing (A8); withdraw the pivot and remove the shift leve...1560
1 Fit a new ‘O’ ring around the end cover (A1) and align the marks which indicate the correct rel...1560
2 Fit a steel thrust washer, followed by a fibre washer, onto the armature shaft at the commutato...1560
3 Fit a new ‘O’ ring around the housing (A14) and apply some grease to the shift lever cams...1560
4 Put the shift lever housing (A8) over the protrusion of the shaft and fit two fibre washers (A9...1561
5 Fit the steel thrust washer (A11) onto the shaft against the pinion assembly. Fit a new ‘O’ rin...1561
6 Tighten evenly the cap screws to 24,4 to 28,3 Nm (216 to 250 lbf in)...1561
7 Check that the armature turns freely and fit the carbon brushes into their holders (A2). Ensure...1561
8 Use a spring balance to check the springs of the carbon brushes. Renew the springs if the loads...1561
9 Spread a thin application of glycerine on the gasket of the cover (A4), and fit the ends of the...1561
10 Fit the solenoid switch as given in operation 23-4...1561
To clean 23-6...1562
To inspect and to correct 23-7...1562
1 Use an ‘Avometer’ to check the resistance of the pull-in coil and the hold-in coil. These shoul...1562
2 Inspect the yoke assembly and the field windings, and also the starter motor housings for damag...1562
3 Inspect the armature for wear and damage, especially the splines. Check that there is no deflec...1562
4 Use suitable equipment to check that the continuity and insulation of the armature windings are...1562
5 Use a growler and a 230 volt test lamp to check the armature for earthing, continuity and open ...1562
6 Test the insulation of the carbon brush holders, and renew the carbon brushes if there is damag...1562
7 Inspect the bushes in the end cover of the commutator and in the pinion housing. If there are i...1562
8 Use the measurements of the old bush to machine a groove in the new bush which aligns with the ...1562
9 Put the end cover, or the pinion housing, in a lathe and ream the new bush to obtain an interna...1562
10 Inspect the bush in the shift lever housing. If necessary, renew the bush and machine an oil g...1562
11 Inspect the shift lever and its shaft for wear and damage, and check that the arrangement whic...1562
12 Check that the contactor disc is not burnt and that there is no erosion. If necessary, clean t...1562
13 Check the contact faces on the heads of the terminals. Renew the terminals if they are burnt o...1562
14 Inspect the assembly of the pinion. Renew the assembly if the components have excessive wear o...1562
To test 23-8...1563
1 Connect a 24 volt supply to terminals 1 and 3, push back the pinion assembly and, using a 4,76 ...1563
2 Replace the rubber plug in the solenoid switch, fit both jumper leads and apply a few drops of ...1563
3 Test the solenoid switch for correct operating sequence, as follows:...1563
To fit the main starter cables 23-9...1563
1 Fit the lugs of the relevant cables to the two terminals. Ensure that the polarity of the cable...1563
2 Hold a 19 mm (0.75 in) A/F spanner on the inner lock nuts to ensure that they do not move while...1563
Engine stop solenoid...1564
How to adjust the linkage 23-10...1564
1 Disconnect the electrical supply, slacken the lock nut (A3) and rotate the rod (A2) until the l...1564
2 Connect a 24 volt DC supply of electricity and energise the solenoid. Ensure that the connectio...1564
3 Ensure that the linkage is fitted to the control lever (C3). Energise the solenoid and move the...1564
4 Hold the lever at this position and adjust the lock nut (C1) until its rear face is level with ...1564
5 Connect the linkage to the solenoid and rotate the rod (C2) until it reaches the lock nut. Hold...1564
6 Energise and de-energise the solenoid to check the operation...1564
Auxiliary equipment...1566
Compressor...1566
To remove and to fit 24-1...1566
1 Using a 5/16 in allen key remove the hydraulic pump and coupling, where fitted, from the rear o...1566
2 Drain the engine coolant into a suitable clean container...1566
3 Disconnect and remove the rubber coolant pipe from between the compressor and the crankcase...1566
4 Remove the compressor air intake filter assembly, or disconnect the air intake pipe from the in...1566
5 Unscrew the steel coolant pipe from the front of the compressor cylinder head. Do NOT bend the ...1566
6 Disconnect the oil feed pipe, free it from its clips, and remove it from the engine...1566
7 Unscrew the three compressor securing nuts and washers...1566
8 Support and carefully withdraw the compressor (A). Discard the gasket...1566
1 If the drive gear has been removed, either refit the original gear or fit a new gear, as required...1567
2 Clean both joint faces and fit a new gasket over the three compressor mounting bolts...1567
3 Slide the compressor into position ensuring that it engages with the camshaft gear. Fit the nut...1567
4 Fit and secure the oil feed pipe and the two coolant pipes...1567
5 Fit the air intake filter assembly or connect the pipe to the induction system (whichever is fi...1567
6 Refill the engine cooling system with coolant...1567
7 Where necessary, fit the hydraulic pump and coupling...1567
Compressor gear alignment 24-2...1568
1 View the compressor crankshaft from the threaded drive end. Looking through the mounting flange...1568
2 With the machined base of the compressor crankcase sitting on a flat surface check that the mac...1568
3 Before fitting the compressor drive gear ensure that both the crankshaft taper and the gear bor...1568
Running-in and test...1570
General description...1570
Running-in and test...1571
To run the engine 25-1...1571
1 Prepare the engine as given in section 3 of the User’s Handbook TSD 3215...1571
2 Start the engine and run it without a load. Check that the oil pressure is correct. Inspect the...1571
3 Correct all leakage and add more lubricating oil and coolant, if necessary, to the correct leve...1571
4 It is possible to overload the engine during phase 5 and, to prevent this, the load and the spe...1571
5 When the schedule is finished and the running-in has been acceptable, check the consumption rat...1571
To check the consumption rate of the engine lubricating oil 25-2...1572
1 Ensure that the level of the engine lubricating oil is exactly to the ‘H’ mark on the dipstick...1572
2 Run the engine at its rated speed and power until the normal temperatures of the coolant and th...1572
3 Run the engine at the minimum load for two minutes. Stop the engine and check the level of the ...1572
4 Drain immediately the engine lubricating oil from the sump and from the heat exchanger into sep...1572
5 Measure separately the weight of each container with its contents and make a record of the weig...1572
6 Fit the drain plugs in the sump and the heat exchanger and return the original engine lubricati...1572
7 Find the difference in the weight of the containers when with and without the lubricating oil. ...1572
8 Run the engine at its rated speed with 90% of the maximum load, for two hours...1572
9 At the end of the two hours, continue to run the engine without load for two more minutes. Stop...1572
List of special tools...1574
Special tools...1575
TSD3409E4 - User’s Handbook (2000 Series_Models 2006SI & 2006TSI_6 cylinder spark ignited engines for industrial applications)...1586
TSD3429E3 - User’s Handbook (Eagle TX2000)...1636
TSD3433E1 - Workshop Manual (Eagle TX & Eagle 800 & Eagle 2000_6 cylinder diesel engines for Trucks)...1686
TSD3449E2 - User’s Handbook (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engines for industrial applications))...1818
TSD3450E - Workshop Manual (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engines for industrial applications))...1878
Perkins 2800 Series...1878
Model 2806C-E16...1878
Workshop manual...1878
6 cylinder turbocharged diesel engines for industrial applications...1878
Chapters...1879
1 General information...1879
2 Specifications...1879
3 Cylinder head assembly...1879
4 Piston and connecting rod assemblies...1879
5 Crankshaft assembly...1879
6 Gear case and drive assembly...1879
7 Crankcase and cylinder liners...1879
8 Engine timing and electronic controls...1879
9 Aspiration system...1879
10 Lubrication system...1879
11 Fuel system...1879
12 Cooling system...1879
13 Flywheel and housing...1879
14 Electrical equipment...1879
15 Auxiliary equipment...1879
16 Special tools...1879
Publication TSD3450E, Issue 2...1878
© Proprietary information of Perkins Engines Company Limited, all rights reserved...1878
The information is correct at the time of print...1878
Published in October 2002 by Technical Publications,...1878
Perkins Engines Company Limited, Shrewsbury SY1 3NX, England...1878
Contents...1880
1 General information...1880
Introduction 1...1880
Safety precautions 2...1880
Viton seals 4...1880
Welding 4...1880
Environmental protection 4...1880
Engine views 5...1880
Engine identification 6...1880
Engine lift equipment 6...1880
2 Specifications...1880
Basic engine data - 2306 engine 7...1880
Basic engine data - 2806 engine 7...1880
Rocker assemblies 8...1880
Valves 9...1880
Valve guides 10...1880
Valve springs 10...1880
Valve seat inserts 11...1880
Cylinder head 12...1881
Camshaft and bearings 12...1881
Pistons and connecting rods - 2306 engine 13...1881
Pistons and connecting rods - 2806 engine 14...1881
Crankshaft, main bearings and flywheel 15...1881
Crankshaft damper 15...1881
Crankcase and cylinder liners 16...1881
Lubricating oil pump 18...1881
Coolant pump 19...1881
Recommended torque figures 20...1881
3 Cylinder head assembly...1881
General information 27...1881
4 Pistons and connecting rod assemblies...1882
General information 57...1882
5 Crankshaft assembly...1882
General information 63...1882
6 Gear case and drive assembly...1882
General information 73...1882
7 Crankcase and cylinder liners...1883
General information 81...1883
8 Engine timing and electronic controls...1883
General information 87...1883
9 Aspiration system...1883
General information 91...1883
10 Lubrication system...1884
General information 95...1884
11 Fuel system...1884
General information 103...1884
12 Cooling system...1884
General information 111...1884
13 Flywheel and housing...1885
General information 129...1885
14 Electrical equipment...1886
General information 133...1886
15 Auxiliary equipment...1886
General information 139...1886
Oil sample valve 139...1886
16 Special tools...1886
List of special tools 141...1886
General information...1888
Introduction...1888
Safety precautions...1889
Viton seals...1891
Welding...1891
Environmental protection...1891
Engine views...1892
Engine identification...1893
Engine lift equipment...1893
Specifications...1894
Basic engine data - 2306 engine...1894
Basic engine data - 2806 engine...1894
Rocker assemblies...1895
Valves...1896
Valve guides...1897
Valve springs...1897
Valve seat inserts...1898
Cylinder head...1899
Camshaft and bearings...1899
Pistons and connecting rods - 2306 engine...1900
Pistons and connecting rods - 2806 engine...1901
Crankshaft, main bearings and flywheel...1902
Crankshaft damper...1902
Crankcase and cylinder liners...1903
Lubricating oil pump...1905
Coolant pump...1906
Recommended torque figures...1907
Standard torque figures for metric fasteners...1907
Metric nuts and bolts...1907
Thread size...1907
metric...1907
Standard torque...1907
Metric taperlock studs...1907
Thread size...1907
metric...1907
Standard torque...1907
Standard torque figures for imperial fasteners...1908
Imperial nuts and bolts...1908
Thread size...1908
inches...1908
Standard torque...1908
Imperial taperlock studs...1908
Thread size...1908
inches...1908
Standard torque...1908
Standard torque figures for ‘O’ ring face seal fittings and 37 degree flared fittings...1909
Torque figures for ferrous straight thread ‘O’ ring fittings when connected to ferrous materials...1909
Outside diameter of nominal tube...1909
Thread size...1909
Inches...1909
Standard...1909
torque...1909
‘O’ ring face seal fittings...1910
Torque figures for ferrous straight thread ‘O’ ring fittings (B)...1910
Thread size...1910
inches...1910
Standards torque...1910
Torque figures for flared and ‘O’ ring fittings...1911
Nuts for 37 degree flared fittings...1911
Outside diameter of nominal tube...1911
Thread size...1911
Inches...1911
Standard...1911
torque...1911
45 degree flared and 45 degree inverted flare fittings...1912
45 degree flared and 45 degree inverted flare fittings...1912
Outside diameter of nominal tube...1912
Thread size...1912
Inches...1912
Standard...1912
torque...1912
Tapered pipe thread fittings...1912
Tapered pipe thread fittings...1912
Thread size...1912
Inches...1912
Standard torque...1912
Threads with pipe sealant (CV60891)...1912
Threads without pipe sealant...1912
Torque figures for standard hose clamps of the worm drive band type...1913
Width of clamp...1913
Torque figure for initial...1913
installation on a new hose...1913
Torque figures for constant torque hose clamps...1913
Cylinder head assembly...1914
General information...1914
Rocker cover...1915
To remove and to fit Operation 3-1...1915
1 Disconnect the wiring harness at the socket on the rocker cover (A1)...1915
2 Disconnect and remove the engine breather pipe (A2)...1915
3 Loosen fully the bolts which retain the rocker cover, but do not remove the bolts from the asse...1915
4 Remove the rocker cover...1915
1 Inspect the seal of the rocker cover and renew if worn of damaged...1915
2 Fit the rocker cover, complete with seal and bolts. Tighten the bolts to a torque of 20 Nm (15 ...1915
3 Fit the engine breather pipe (A2)...1915
4 Connect the wiring harness. Ensure that the wiring harness is fully engaged with the connector...1915
Rocker lever and rocker shaft assemblies...1916
To remove and to fit Operation 3-2...1916
1 Remove the rocker cover, Operation 3-1...1916
2 The valve rocker levers (A1) and the unit injector rocker levers (A2) can move on the shaft (A6...1916
3 Remove the four bolts (A5)...1916
4 Remove the shaft (A6), valve rocker levers (A1) and unit injector rocker levers (A2) as a unit...1916
5 Repeat steps 1 and 2 for the rocker shaft assemblies which remain...1916
1 Loosen the adjustment screws (A3 and A4) of each of the rocker levers which have been removed. ...1916
2 Set the tappet clearances, Operation 3-4...1916
3 Check/adjust the unit injectors, Operation 3-13...1916
4 Fit the rocker cover, Operation 3-1...1916
To dismantle and to assemble Operation 3-3...1917
1 Slide the valve rocker levers (A3) and the unit injector rocker levers (A4) from the shaft (A7)...1917
2 Remove the button (A1) from the adjustment screw (A2) in the valve rocker lever (A3)...1917
3 Remove the button (A6) from the adjustment screw (A5) in the unit injector rocker lever (A4)...1917
4 Repeat steps 1 to 3 for the rocker lever assemblies which remain...1917
1 Install new ‘O’ ring seals in the buttons (A1)...1918
2 Install new ‘O’ ring seals in the buttons (A6)...1918
3 To fit the ‘O’ ring seals and buttons to the valve rocker levers, proceed as follows:...1918
4 To fit the ‘O’ ring seals and buttons to the unit injector rocker levers, proceed as follows:...1918
5 Repeat steps 3 and 4 for the rocker levers which remain...1918
6 Fit the assembled rocker levers to the shafts (A7). Ensure that they are fitted to their origin...1918
How to check/adjust the tappet clearances Operation 3-4...1919
Special tools...1919
Tappet clearances...1919
Description...1919
Part number...1919
Inlet...1919
Exhaust...1919
1 Remove the rocker cover, Operation 3-1...1919
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...1919
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...1919
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...1919
5 Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the pisto...1920
6 Before each set of tappet clearances is adjusted, ensure that the roller of the rocker lever is...1920
7 Use a set of feeler gauges, inserted at the position shown (B3) between the valve bridge piece ...1920
8 After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a ...1921
9 Withdraw the timing bolt and rotate the flywheel by 360 degrees so that the number 6 piston is ...1921
10 Check the tappet clearances for the inlet valves (C1) on cylinders 3, 5 and 6. Adjust the clea...1921
11 After each unit has been adjusted, tighten the lock nut of the adjustment screw to a torque of...1921
12 Check again the tappet clearances for all six cylinders...1921
13 Fit the rocker cover. Remove the engine turning tool and the timing bolt and fit the cover to ...1921
Cylinder head assembly...1922
To remove and to fit Operation 3-5...1922
Special tools...1922
Consumable products...1922
Description...1922
Part number...1922
Description...1922
Part number...1922
1 Remove the thermostat housing, Operation 12-10...1922
2 Remove the exhaust manifold, Operation 9-1...1922
3 Remove the rocker lever and rocker shaft assemblies, Operation 3-2...1922
4 Remove the electronic unit injectors, Operation 3-12...1922
5 Remove the gear case cover, Operation 6-1...1922
6 Disconnect the cable and remove the timing sensor from the cylinder head...1922
7 Remove the support bracket which is fitted between the gear case and the cylinder head...1922
8 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bol...1922
9 Disconnect the fuel lines from the front and rear of the cylinder head. Fit temporary covers to...1922
10 Remove the cylinder head bolts; use the special socket, GE50020...1922
11 Fit the lifting bracket (A1), VP12712, to the cylinder head and attach a suitable hoist. Remov...1922
12 Remove the cylinder head gasket (B4)...1923
13 Remove the ‘O’ ring seal from the oil transfer tube (B6) and remove the 24 coolant seals (B3)...1923
14 Remove the seal (B2)...1923
15 Remove the spacer plate (B5) and discard the spacer plate gasket...1923
16 Remove the second ‘O’ ring seal from the oil transfer tube (B6)...1923
1 If the oil transfer tube (B6) has been removed, apply retaining compound, 21820 638, and insert...1924
2 If the rear dowel has been removed, apply retaining compound, 21820 638, and insert it in the c...1924
3 If the front dowel, close to the oil transfer tube, has been removed, it must be fitted in a dr...1924
4 Fit suitable guide studs (B1) to the cylinder block. Fit a new spacer plate gasket over the dow...1924
5 Fit a new ‘O’ ring seal to the oil transfer tube (B6)...1924
6 Fit the spacer plate (B5) and fit the second ‘O’ ring seal to the oil transfer tube (B6). Fit t...1924
7 Check, and if necessary adjust, the protrusion of the cylinder liners, Operation 7-3...1924
8 Fit a new cylinder head gasket (B4) to the spacer plate...1924
9 Fasten a hoist to the cylinder head, use the lifting bracket VP12712, and lower the cylinder he...1925
10 Apply special lubricant, CV60895, to the washers, the threads and under the heads of the bolts...1925
11 Fit the camshaft gear. Check and, if necessary, adjust the backlash between the camshaft gear ...1925
12 Fit the gear case cover, Operation 6-1...1925
13 Fit the support bracket between the cylinder head and the gear case...1925
14 Fit the electronic unit injectors, Operation 3-12...1925
15 Fit the rocker lever and shaft assemblies, Operation 3-2...1925
16 Fit the exhaust manifold, Operation 9-1...1925
17 Fit the thermostat housing, Operation 12-10...1925
18 Remove the covers from the fuel lines and from the fuel line ports on the cylinder head. Conne...1925
19 Fit the timing sensor and connect the cable...1925
Valve springs...1926
To remove and to fit Operation 3-6...1926
Special tools...1926
Description...1926
Part number...1926
1 Remove the rocker lever and rocker shaft assemblies, Operation 3-2...1926
2 Remove the electronic unit injectors, Operation 3-12...1926
3 Set the piston for the relevant valve spring assembly to the top of its compression stroke...1926
4 Use the hold-down clamp from the electronic unit injector to secure the valve spring compressor...1926
5 Insert the stud and base of the valve spring compressor into the bore of the injector sleeve. U...1926
6 Tighten the nut until the collets are loose on the valves...1926
7 Remove two collets from each valve...1926
8 Loosen slowly, then remove the nut, washer, thrust bearing and plate...1926
9 Remove the rotocoils, valve springs and washers from each valve...1926
10 Inspect the valve springs, refer to Chapter 2, Specifications for the correct dimensions and s...1926
11 Repeat steps 3 to 10 for the other valve spring assemblies which are to be removed...1926
1 Apply clean engine oil to the relevant valve stems...1927
2 Fit the washer, valve spring and rotocoil to each valve...1927
3 Use the valve spring compressor, GE50026, to compress the valve springs...1927
4 Fit two collets to each valve...1927
5 Loosen slowly and then remove the nut (A2) and plate (A1) of the valve spring compressor. Remov...1927
6 Tap lightly each valve with a soft hammer to ensure that the collets are seated correctly...1927
7 Fit the electronic unit injectors, Operation 3-12...1927
8 Fit the rocker lever and rocker shaft assemblies, Operation 3-2...1927
Valves...1928
To remove and to fit Operation 3-7...1928
Special tools...1928
Description...1928
Part number...1928
1 Remove the cylinder head, Operation 3-5...1928
2 Put the cylinder head, flame face down, on a bench with a soft surface and release the valves b...1928
3 Withdraw the valves from the cylinder head...1928
4 Repeat the procedure for all valves which are to be removed...1928
1 Apply clean engine oil to the stems of the valves. Fit the valves to their original positions i...1928
2 Use the special tool, GE50026, and the procedure given in Operation 3-6, to install the valve s...1928
3 Fit the cylinder head, Operation 3-5...1928
Valve seals...1929
To renew Operation 3-8...1929
Special tools...1929
Description...1929
Part number...1929
1 Remove the relevant valve spring assembly, Operation 3-6...1929
2 Remove the valve seal from the valve and valve guide...1929
3 Apply a thin film of clean engine oil to the new valve seal and slide the seal over the valve s...1929
4 If the valve seal is to be fitted to a valve guide with the valve removed, fit the seal to the ...1929
5 Use the special tool, GE50027, and hand pressure only to push the valve seal into its position ...1929
6 Withdraw the tool and fit the valve spring assembly, Operation 3-6...1929
Valve guides...1930
To remove and to fit Operation 3-9...1930
Special tools...1930
Description...1930
Part number...1930
1 Remove the cylinder head, Operation 3-5...1930
2 Remove the valves, Operation 3-7...1930
3 Use the special tool (A1), GE50043, and a hammer to drive the valve guide (A2) from the cylinde...1930
1 Apply clean engine oil to the outside diameter of the new valve guides...1931
2 Use the special tool (B1), GE50043, together with the sleeve (B2), GE50044, to install the valv...1931
3 When a new valve guide has been fitted, check that there is full contact between the valve and ...1931
4 Fit the valves, Operation 3-7...1931
5 Fit the cylinder head, Operation 3-5...1931
Camshaft...1932
To remove and to fit Operation 3-10...1932
Special tools...1932
Consumable products...1932
Description...1932
Part number...1932
Description...1932
Part number...1932
1 Remove the radiator, Operation 12-4...1932
2 Remove the fan, Operation 12-5...1932
3 Remove the gear case cover, Operation 6-1...1932
4 Remove the rocker cover, Operation 3-1...1932
5 Remove the rocker lever and shaft assemblies, Operation 3-2...1932
6 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...1932
7 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...1932
8 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...1933
9 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case...1933
10 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bo...1933
11 Attach a hoist to the camshaft gear and withdraw the gear from the camshaft. Remove the guide ...1933
12 Remove three bolts and withdraw the thrust plate, the adaptor plate and the seal assembly...1933
13 Use the bolts of the rocker shaft to retain the cradle tool (B1), GE50018, at the position sho...1933
14 Remove the rear cover (C1), complete with seal (C3)...1934
15 Fit the camshaft guide (D1), GE50017, to the gear case. Do not tighten the bolts for the guide...1934
16 Install a pilot tool, GE50015, into the threaded hole at the rear end of the camshaft. Then at...1934
17 Withdraw the camshaft until it enters the bore of the camshaft guide. Tighten the bolts which ...1934
18 Use the lifting hooks, GE50025, to move the camshaft toward the front of the engine...1934
19 Withdraw the camshaft from the cylinder head just enough for a strap and hoist to be attached...1934
1 Fit the two pilot tools, GE50015, to the rear end of the camshaft. Ensure that the camshaft and...1935
2 Fit the camshaft guide (E1), GE50017, to the gear case cover, but do not tighten the bolts fully...1935
3 Insert the alignment sleeve (E2), GE50016, through the camshaft guide (E1) and into the camshaf...1935
4 Fit the cradle tool (F1), GE50018, at the position shown (F)...1935
5 Use a suitable strap and hoist to support the camshaft. Insert the camshaft through the guide a...1935
6 Remove the strap and hoist. Rotate the camshaft during installation. Do not allow the end of th...1935
7 Remove the pilot tools and push the camshaft fully into its bore...1935
8 Inspect the seal (G3) and renew if necessary. Fit the rear cover (G1), complete with seal (G3)...1935
9 Remove the cradle tool and the camshaft guide...1936
10 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubric...1936
11 Fit the guide stud, GE50019, to the camshaft...1936
12 Fit the camshaft gear; align the hole in the gear with the dowel pin on the adapter plate. If ...1936
13 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tig...1936
14 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the...1936
15 Fit the gear case cover, Operation 6-1...1936
16 Remove the timing bolt from the flywheel and fit the cover and plug...1936
17 Install the rocker lever and shaft assemblies, Operation 3-2...1936
How to set the backlash for the camshaft gear Operation 3-11...1937
1 Remove the main idler gear (A3). Hold the camshaft gear stationary and use a dial test indicato...1937
2 Fit the main idler gear (A3), hold the main idler gear stationary and measure the backlash on t...1937
3 To adjust the backlash, remove the three bolts and thrust plate which retain the adjustable idl...1937
4 Fit the idler gear. Retain with the thrust plate and three bolts. Check again the backlash betw...1937
5 When the correct backlash settings have been obtained, remove the adjustable idler gear and pro...1937
Electronic injector units...1938
To remove and to fit Operation 3-12...1938
Special tools...1938
Description...1938
Part number...1938
Description...1938
Part number...1938
1 Remove the relevant rocker shaft assembly, Operation 3-2...1938
2 Loosen the two nuts and remove the electrical connector from the injector unit...1938
3 Mark the valve bridge pieces to assist during assembly, then remove them...1938
4 Remove the bolt (A2) from the spacer and clamp which retain the injector unit and use the speci...1938
5 Remove the injector unit, together with the spacer and clamp...1938
6 Use the vacuum pump, GE50028, together with the tube, GE50030, and bottle, GE50029, to extract ...1938
1 Clean thoroughly the bore of the injector sleeve and cylinder head. Use the special brushes (GE...1939
2 Check the condition of the ‘O’ ring seals (B1 and B2); renew the seals if they are worn or dama...1939
3 Fit the injector unit to the cylinder head. Fit the clamp, spacer and retaining bolt. Tighten t...1939
4 Fit the bridge pieces...1939
5 Attach the electrical connector to the injector unit and retain with the two nuts. Tighten the ...1939
6 Fit the rocker shaft assembly, Operation 3-2...1939
To check and to adjust Operation 3-13...1940
Special tools...1940
Description...1940
Part number...1940
1 With the rocker covers removed, set the number 1 piston to TDC (top dead centre) on its compres...1940
2 Use the fuel injector setting gauge, CH11149, to obtain the correct height for the fuel injecto...1940
3 Remove the timing bolt from the flywheel housing and rotate the flywheel by 360 degrees in the ...1940
4 Check/adjust the height dimensions for the fuel injectors of cylinders 1, 2 and 4 as given in s...1940
Injector sleeves...1941
To remove and to fit Operation 3-14...1941
Special tools...1941
Description...1941
Part number...1941
Description...1941
Part number...1941
1 Remove the rocker shaft assemblies, Operation 3-2...1941
2 Remove the electronic injector units, Operation 3-12...1941
3 Mark the bridge pieces and make a note of their position to assist during assembly, then remove...1941
4 Fit the puller stud from the special tool, GE50021, into the injector sleeve as shown (A). Fit ...1941
5 Remove the ‘O’ ring seals from the injector sleeve. Check the condition of the injector sleeve ...1941
6 Repeat steps 1 to 5 for the injector sleeves which remain...1941
1 Use the brushes, special tool numbers: GE50023, GE50024 and GE50022, to clean thoroughly the bo...1942
2 Fit new ‘O’ ring seals to the injector sleeve...1942
3 Fit the stud from the special tool into the threads of the injector sleeve...1942
4 Apply CV60889 anti-seize compound to the ‘O’ ring seals and to the large diameter (B1) off the ...1942
5 Apply CV60893 retaining compound to the small diameter (B2) off the injector sleeve...1942
6 Using the stud, insert the injector sleeve into its bore in the cylinder head. Take care to pre...1942
7 Fit the driver tool over the stud and tap lightly with a hammer to ensure that the injector sle...1942
8 Use a clean cloth to remove any retaining or anti-seize compound from the bores of the cylinder...1942
9 Fit the electronic injector units, Operation 3-12...1942
10 Fit the rocker shaft assemblies, Operation 3-2...1942
Pistons and connecting rod assemblies...1944
General information...1944
Pistons and connecting rod assemblies...1945
To remove and to fit Operation 4-1...1945
Special tools...1945
Consumable products...1945
Description...1945
Part number...1945
Description...1945
Part number...1945
1 Remove the cylinder head assembly, Operation 3-5...1945
2 Remove the oil pump, Operation 10-4...1945
3 Remove the stiffener plate from the base of the crankcase...1945
4 Remove the carbon ridge from the top inside surface of the cylinder liners...1945
5 Turn the crankshaft until two pistons are at bottom centre...1945
6 Remove the bolts (A1) and the bearing caps. Push the connecting rods and pistons up until the r...1945
7 Withdraw carefully the pistons and connecting rods from the cylinder liners. Store the bearing ...1945
8 Repeat steps 3 to 6 for the remainder of the pistons and connecting rods...1945
1 Apply clean engine oil to the piston rings, the connecting rod bearings and the cylinder liners...1946
2 Ensure that the piston ring gaps are set at 120 degree intervals to each other...1946
3 Use the special tool (B1), GE50003 for 2806 engines or GE50045 for 2306 engines, to install the...1946
4 Fit the bearing cap to the connecting rod. The cap must be fitted with its number on the same s...1946
5 Apply anti-seize compound, CV60890, to the bolt threads. Install the bolts and bearing cap. Tig...1946
6 Repeat steps 1 to 4 for the remainder of the pistons and connecting rods...1946
7 Fit the stiffener plate to the base of the crankcase...1946
8 Fit the oil pump, Operation 10-4...1946
9 Fit the cylinder head assembly, Operation 3-5...1946
To dismantle and assemble Operation 4-2...1947
1 Remove the pistons and connecting rod assemblies, Operation 4-1...1947
2 Remove the big-end bearing shells (A5) from the connecting rod (A4) and connecting rod cap. If ...1947
3 Remove the circlips (A1)...1947
4 Remove the gudgeon pin (A2) and separate the connecting rod and the piston crown from the piston...1947
5 Remove carefully the piston rings (A3) from the piston crown and clean the piston ring grooves ...1947
1 Check the gaps between the ends of the piston rings when the rings are inserted in a new liner...1948
2 Fit the spring of the oil control ring to its groove in the piston crown...1948
3 Use a suitable piston ring expander to fit the oil control ring to its groove in the piston crown...1948
4 Fit the second (intermediate) piston ring with the side that has the identification "UP-2" towa...1948
5 Fit the first (top) piston ring with the side that has the identification "UP-1" toward the top...1948
6 When all three piston rings have been fitted, adjust the position of the piston ring gaps so th...1948
7 Fit the piston crown into the piston skirt and insert the connecting rod. Apply clean engine oi...1948
8 Fit the big-end bearings to the connecting rod (A4) and connecting rod cap. If the original bea...1948
9 Fit the pistons and connecting rod assemblies, Operation 4-1...1948
Piston cooling jets...1949
To remove and to fit Operation 4-3...1949
Special tools...1949
Description...1949
Part number...1949
1 Remove oil pump, Operation 10-4...1949
2 Use the engine turning tool, CH11148, to turn the crankshaft in a clockwise direction (as seen ...1949
3 Remove the bolt which retains the cooling jet and remove the cooling jet from the engine...1949
4 Repeat steps 2 and 3 for the cooling jets which remain...1949
1 Before a piston cooling jet is fitted to the engine, use the jet alignment tool, GE50004, to en...1949
2 Carefully fit the piston cooling jets to the engine, ensure that the nozzles of the cooling jet...1949
3 Fit the oil pump, Operation 10-4...1949
Crankshaft assembly...1950
General information...1950
Crankshaft...1951
To remove and to fit Operation 5-1...1951
Consumable products...1951
Description...1951
Part number...1951
1 Remove the gear case cover, Operation 6-1...1951
2 Remove the flywheel housing, Operation 13-2...1951
3 Remove the pistons and connecting rod assemblies, Operation 4-1...1951
4 Remove the crankshaft rear seal and wear sleeve, Operation 5-3...1951
5 Remove the crankshaft front seal and wear sleeve, Operation 5-2...1951
6 Remove the bolts (A1) which retain the main bearing caps in the crankcase and remove the bearin...1951
7 Fit one of the bolts from the front pulley to each end of the crankshaft. Fasten a hoist to the...1951
1 Clean the crankcase and the main bearing caps thoroughly. Apply clean engine oil to the main be...1952
2 Install one of the bolts from the front pulley in each end of the crankshaft, fasten a suitable...1952
3 Fit the thrust bearings for the centre main bearing. Ensure that the bearings are fitted with t...1952
4 Fit the main bearings to the bearing caps...1952
5 Ensure that the tabs on the back of the bearing shells fit into the tab slots of the bearing ca...1952
6 Apply anti-seize compound, CV60890, to the bolts and install the main bearing caps and bolts...1952
7 Begin at the tab end of the bearing cap first, tighten each bearing cap bolt to a torque of 260...1952
8 Use a dial test indicator (DTI) to check the end-float of the crankshaft. Ensure that the point...1952
9 Fit the crankshaft front seal and wear sleeve, Operation 5-2...1952
10 Fit the crankshaft rear seal and wear sleeve, Operation 5-3...1952
11 Fit the pistons and connecting rod assemblies, Operation 4-1...1952
12 Fit the flywheel housing, Operation 13-2...1952
13 Fit the gear case cover, Operation 6-1...1952
Crankshaft front seal and wear sleeve...1953
To renew Operation 5-2...1953
Special tools...1953
Consumable products...1953
Description...1953
Part number...1953
Description...1953
Part number...1953
1 Remove the vibration damper, Operation 5-4...1953
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapp...1953
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the ...1953
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With ...1953
5 Remove the distorter tool, the protection ring and the wear sleeve...1953
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure prime...1954
2 Use the bolts (C3), GE50009, to install the guide, GE50008, on the crankshaft...1954
3 Fit the wear sleeve and seal (C4) as a unit onto the locator, GE50008...1954
4 Fit the installer (C2), GE50012, onto the locator...1954
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the ins...1954
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in ...1954
7 Remove all of the tools from the crankshaft...1954
8 Fit the vibration damper, Operation 5-4...1954
Crankshaft rear seal and wear sleeve...1955
To renew Operation 5-3...1955
Special tools...1955
Consumable products...1955
Description...1955
Part number...1955
Description...1955
Part number...1955
1 Remove the flywheel, Operation 13-1...1955
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapp...1955
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the ...1955
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With ...1955
5 Remove the distorter tool, the protection ring and the wear sleeve...1955
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure prime...1956
2 Use the bolts (C4), GE50009, to install the guide, GE50008, on the crankshaft...1956
3 Fit the wear sleeve and seal (C3) as a unit onto the locator, GE50008...1956
4 Fit the installer (C2), GE50012, onto the locator...1956
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the ins...1956
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in ...1956
7 Remove all of the tools from the crankshaft...1956
8 Fit the flywheel, Operation 13-1...1956
Crankshaft vibration damper...1957
To remove and to fit Operation 5-4...1957
1 Remove the fan guards...1957
2 Slacken the tension on the fan drive belts, then remove the belts from the crankshaft pulley (A1)...1957
3 Attach a strap and a suitable lifting device to the vibration damper (A2). Remove the six bolts...1957
4 Remove damper and adapter. The weight of the vibration damper is approximately 25 kg (55 lb)...1957
1 Attach a strap and a suitable lifting device to the vibration damper (A2). Use a 5/8 -18 x 6 in...1958
2 Fit the crankshaft pulley (A1). Apply clean engine oil to the threads of the bolts and install ...1958
3 Remove the guide stud and install the final bolt and washer. Tighten the bolts to a torque of 2...1958
4 Fit the fan belts and adjust the tension as given in Operation 12-7...1958
5 Fit the fan guards...1958
Gear case and drive assembly...1960
General information...1960
Gear case cover...1961
To remove and to fit Operation 6-1...1961
1 Remove the radiator, Operation 12-4...1961
2 Remove the fan, Operation 12-5...1961
3 Loosen the bolts which retain the gear case cover. Do not remove the bolts from the assembly, a...1961
4 Remove the gear case cover...1961
1 Examine the seal and renew if necessary, clean the contact surfaces of the seal and the gear case...1961
2 Fit the gear case cover and tighten the bolts, in the sequence shown (A), to a torque of 20 Nm ...1961
3 Fit the fan, Operation 12-5...1961
4 Fit the radiator, Operation 12-4...1961
Timing gears...1962
To remove and to fit Operation 6-2...1962
Special tools...1962
Consumable products...1962
Description...1962
Part number...1962
Description...1962
Part number...1962
1 Remove the gear case cover, Operation 6-1, and set the engine to the correct timing position fo...1962
2 Remove the top bolt (A1) from the cover (A2) on the flywheel housing and loosen the other cover...1962
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...1962
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...1962
5 Remove the rocker lever and rocker shaft assemblies, Operation 3-2. If the camshaft gear (C2) i...1963
6 Remove the camshaft gear (C2), if relevant. Use the guide stud, GE50019. If the gear case is to...1963
7 Remove the three bolts and the thrust plate (C3) and remove the adjustable idler. Discard the b...1963
8 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...1963
9 Remove the three bolts and the thrust plate (C4) and remove the main idler. Discard the bolts...1963
10 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...1963
11 Remove the four bolts and the thrust plate (C1) and withdraw the compound idler. Discard the b...1963
12 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...1963
13 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaf...1963
14 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is w...1963
15 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diamet...1963
1 Fit the assembly of the compound idler to its shaft, ensure that the "V" timing mark on the cra...1964
2 Fit the main idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Apply th...1964
3 Fit the adjustable idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Ap...1964
4 Fit the camshaft gear, if it was removed: align the hole in the gear with the dowel pin on the ...1964
5 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tigh...1964
6 Fit the gear case cover, Operation 6-1...1964
7 Remove the timing bolt from the flywheel and fit the cover and plug...1964
8 Install the rocker lever and shaft assemblies, Operation 3-2...1964
How to check the position of the timing gears Operation 6-3...1965
Gear case...1966
To remove and to fit Operation 6-4...1966
Consumable products...1966
Description...1966
Part number...1966
1 Remove the gear case cover, Operation 6-1...1966
2 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case...1966
3 Disconnect the lead and remove crankshaft timing sensor from behind the bottom of the gear case...1966
4 Remove the fan drive assembly, Operation 12-6...1966
5 Remove the coolant pump, Operation 12-13...1966
6 Remove the crankshaft vibration damper, Operation 5-4...1966
7 Remove the front engine support, Operation 7-1...1966
8 Remove the sump, Operation 10-3...1966
9 Remove the fuel transfer pump, Operation 11-2. If necessary, remove the drive for the fuel tran...1966
10 Remove the timing gears and the camshaft drive gear, Operation 6-2...1966
11 Remove the bolt and five nuts which retain the axle for the adjustable idler...1966
12 Remove the bolt and five nuts which retain the axle for the main idler...1966
13 Remove the three bolts which retain the camshaft front seal assembly. Remove the thrust plate,...1966
14 Attach a suitable hoist to the gear case and remove the mounting bolts...1966
15 Remove the gear case from the dowels in the crankcase. The weight of the gear case is approxim...1966
1 Clean thoroughly the contact surfaces of the crankcase and gear case...1967
2 Fit the two dowels, if they have been removed, and ensure that they protrude from the crankcase...1967
3 Ensure that the front surface of the crankcase is clean and fit a new joint to the crankcase...1967
4 Ensure that the rear face of the gear case is clean and fit the gear case onto the crankcase. F...1967
5 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaft...1967
6 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is wo...1967
7 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diamete...1967
8 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubrica...1967
9 Fit the timing gears, Operation 6-2...1967
10 Fit the sump, Operation 10-3...1967
11 Fit a new crankshaft front seal and wear sleeve, Operation 5-2...1967
12 Fit the front engine support, Operation 7-1...1967
13 Fit the crankshaft vibration damper, Operation 5-4...1967
14 Fit the coolant pump, Operation 12-13...1967
15 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the...1967
16 Fit the crankshaft timing sensor to its location behind the bottom of the gear case and connec...1967
17 Fit the gear case cover, Operation 6-1...1967
Crankcase and cylinder liners...1968
General information...1968
Front engine support...1969
To remove and to fit Operation 7-1...1969
1 Remove the radiator, Operation 12-4...1969
2 Use a suitable hoist, attached to the front lifting bracket, to support the engine and remove t...1969
3 Remove the eight bolts and washers (A1) and remove the engine support...1969
1 Fit the front engine support to the engine and retain with eight bolts and washers (A1)...1969
2 Attach the engine support to the base frame with the relevant bolts (A2), remove the hoist from...1969
3 Fit the radiator, Operation 12-4...1969
Cylinder liners...1970
To remove and to fit Operation 7-2...1970
Special tools...1970
Consumable products...1970
Description...1970
Part number...1970
Description...1970
Part number...1970
1 Remove the pistons and connecting rod assemblies, Operation 4-1...1970
2 Fit covers over the journals of the crankshaft for protection from dirt or water...1970
3 Use the special tool (A1), GE50001, to remove the cylinder liners (A2). Make a note of the bore...1970
1 Clean the cylinder liners and the liner bores in the crankcase...1970
2 Install the cylinder liners in the cylinder block without the ‘O’ ring seals or the filler band...1970
3 Check the protrusion of the cylinder liners, Operation 7-3...1970
4 Remove the liners and fit new ‘O’ ring seals...1970
5 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upp...1970
6 After the engine oil or liquid soap has been applied, immerse the filler band in clean engine o...1970
7 Fit the pistons and connecting rod assemblies, Operation 4-1...1970
To check and to adjust the protrusion of the cylinder liners Operation 7-3...1971
Special tools...1971
Description...1971
Part number...1971
Description...1971
Part number...1971
1 Ensure that the top face of the cylinder block (A4) is clean. Fit a new spacer plate gasket and...1971
2 Fit the cylinder liners to the cylinder block without seals or bands. Ensure that the cylinder ...1971
3 Install all of the bolts (A6), GE50005, or the six bolts around the liner (A5) to be checked. A...1971
4 Use the special tool, GE50002, to measure the liner protrusion at the four positions shown (B1,...1971
5 Add the four readings for each cylinder and divide the sum of the readings by four to obtain th...1971
6 If the liner protrusions are all below the specifications or low in the range, 0,025 mm (0.001 ...1972
7 When the liner protrusion is correct, add a temporary mark to the liner and to the spacer plate...1972
8 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upp...1972
Engine timing and electronic controls...1974
General information...1974
Electronic control module...1975
To remove and to fit Operation 8-1...1975
1 Switch off the engine and disconnect the electrical power supply...1975
2 Loosen fully the Allen screws from the J1 and J2 connectors (A1 and A4)...1975
3 Remove the two nuts which retain the bar (A6) and the control module (A3), release the ground s...1975
4 Support the control module, remove the two remaining nuts (A2 and A5) and remove the electronic...1975
1 Fit the electronic control module. Retain with four nuts, ensure that the ground strap is fitte...1975
2 Fit the connectors (A1 and A4) and retain with Allen screws. Tighten the screws to a torque of ...1975
3 Connect the electrical power supply...1975
Engine timing...1976
To check Operation 8-2...1976
Special tools...1976
Description...1976
Part number...1976
1 With the engine switched off and electrically isolated, remove the rocker cover, Operation 3-1...1976
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...1976
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...1976
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...1976
5 Attach a plunger clock and set the plunger on the top face of the rocker lever of the number on...1977
6 Rotate the engine in the normal direction of rotation until the timing bolt can again enter the...1977
7 Repeat step 6 to ensure that a consistent reading is obtained...1977
8 If the reading is not within the limits, adjust the position of the adjustable idler gear to ad...1977
Aspiration system...1978
General information...1978
Exhaust manifold...1979
To remove and to fit Operation 9-1...1979
Special tools...1979
Consumable products...1979
Description...1979
Part number...1979
Description...1979
Part number...1979
1 Remove the turbocharger, Operation 9-2...1979
2 Remove the thermostat housing, Operation 12-10...1979
3 Remove the exhaust shield...1979
4 Remove the nuts and spacers which retain the exhaust manifold and remove the manifold...1979
5 Withdraw the sleeves from the cylinder head...1979
6 Remove the gaskets from the cylinder head...1979
1 Check the condition of all sleeves, studs and nuts. Renew the components if worn or damaged. Ap...1979
2 Fit new gaskets over the studs and install the sleeves. Fit the exhaust manifold, fit the space...1979
3 Fit the thermostat housing, Operation 12-10...1979
4 Fit the turbocharger, Operation 9-2...1979
Turbocharger...1980
To remove and to fit Operation 9-2...1980
1 Disconnect the exhaust pipe from the turbocharger...1980
2 Remove the air duct from between the turbocharger and the air cleaner...1980
3 Disconnect the air duct from between the turbocharger and the charge air cooler...1980
4 Disconnect the oil feed (A2) and oil drain (A1) pipes...1980
5 Use a strap and hoist to support the turbocharger, remove the four bolts which retain the turbo...1980
1 Fit the turbocharger to the exhaust manifold. Apply CV60889 anti-seize compound to the bolts. F...1980
2 Connect the oil feed and oil drain pipes (A2 and A1)...1980
3 Fit the air duct between the turbocharger and the air cleaner...1980
4 Connect the air duct between the turbocharger and the charge air cooler...1980
5 Connect the exhaust pipe...1980
To dismantle and to assemble Operation 9-3...1981
1 Remove turbocharger, Operation 9-2...1981
2 Add temporary alignment marks between the bearing housing and both the compressor housing and t...1981
3 Loosen the nuts on the clamps and separate the compressor housing and the turbine housing from ...1981
4 Check the condition of all components. Renew any worn or damaged components...1981
1 Fit the compressor housing and the turbine housing to the bearing housing and retain with the r...1981
2 Adjust the position of both the compressor and turbine housings until the temporary marks are a...1981
3 Fit the turbocharger, Operation 9-2...1981
Lubrication system...1982
General information...1982
Oil filter and oil filter header...1983
To remove and to fit Operation 10-1...1983
1 Remove the plug (A5) and drain the oil from the oil filter housing...1983
2 Remove the oil filter housing (A3), and remove the oil filter element...1983
3 Remove the four bolts (A1) which connect the oil filter header to the oil cooler...1983
4 Remove the two bolts (A2) which retain the oil filter header on the crankcase...1983
5 Disconnect the turbocharger oil supply pipe from the elbow behind the oil cooler...1983
6 Remove the four bolts which retain the assembly of the elbow and oil filter header on the crank...1983
7 Remove the four bolts to separate the oil filter header from the elbow. Renew the ‘O’ ring seal...1983
1 Ensure that the ‘O’ ring seals are fitted to the elbow. Assemble the elbow and oil filter heade...1984
2 Ensure that the used gasket material has been removed from the mating faces. Fit the assembly t...1984
3 Fit the four bolts (A1) which retain the oil filter header to the oil cooler...1984
4 Connect the turbocharger oil supply pipe and tighten securely...1984
5 Clean the filter housing (A3) and clean the contact face of the filter head. Clean the drain pl...1984
6 Fit a new element into the filter housing, ensure that it engages fully with the guide in the b...1984
7 Fit the housing (A3) onto the filter head and tighten by use of a socket and torque wrench on t...1984
8 Check the amount of engine oil in the sump. If necessary, add more oil of the correct grade and...1984
9 Run the engine and check for leaks. Check again the amount of engine oil in the sump. If necess...1984
Oil filter header...1985
To dismantle and to assemble Operation 10-2...1985
1 Remove the two plugs (A5 and A6) which retain the by-pass valves in the oil filter header (A1)...1985
2 Remove the spring (A3) and the plunger (A2) for the oil cooler by-pass valve. Remove the spring...1985
3 Remove the two small plugs and the adaptor...1985
1 Fit the plunger (A9) and spring (A8) to the oil filter header...1985
2 Fit the plunger (A2) and spring (A3) to the oil filter header...1985
3 Fit the plugs (A5 and A6). Tighten each plug to 100 +/- 15 Nm (74 +/- 11 lbf ft)...1985
4 Fit the adaptor and the two small plugs. Tighten each of them to 25 +/- 5 Nm (18 +/- 4 lbf ft)...1985
Sump...1986
To remove and to fit Operation 10-3...1986
Consumable products...1986
Description...1986
Part number...1986
1 Drain the oil from the sump (A2)...1986
2 Loosen the bolts which retain the sump on the engine. Do not remove the bolts fully, allow them...1986
3 Remove the sump...1986
1 Examine the sump seal and renew if necessary. Ensure that the machined surface of the sump is c...1987
2 Clean the bottom face of the crankcase and also the bottom faces of the flywheel housing and th...1987
3 Apply a bead of RTV silicone sealant, CV60888, at the four positions where the edge of the flyw...1987
4 Fit the sump and tighten the bolts to a torque of 30 Nm (22 lbf ft); use the sequence shown (B)...1987
5 Fill the engine to the correct level with oil of the correct grade and specification. Refer to ...1987
Oil pump...1988
To remove and to fit Operation 10-4...1988
1 Remove the sump, Operation 10-3...1988
2 Remove the oil supply tube (A3) and the strainer and tube (A2)...1988
3 Remove the bolts and remove the oil pump (A4)...1988
1 Fit the oil pump to the crankcase...1988
2 Apply clean engine oil to the ‘O’ ring seals of the tubes...1988
3 Install oil supply tube (A3) and strainer and tube (A2)...1988
4 Fit the sump, Operation 10-3...1988
To dismantle and to assemble Operation 10-5...1989
1 Remove the bolt and washer which retain the gear on the shaft...1989
2 Use a suitable gear puller to remove drive gear (A1) from the shaft. Remove the key from the sh...1989
3 Remove retainer (A5) for the by-pass valve...1989
4 Remove the spring (A4) and the by-pass valve (A3)...1989
5 Remove the cover (A6) from the pump body (A2)...1989
6 Remove the idler gear and drive gear from pump body...1989
1 Apply clean engine oil to the idler gear and drive gear and install the gears in the oil pump b...1989
2 Fit the by-pass valve, the spring and the retainer to the pump body (A2)...1989
3 Fit the key to the shaft...1989
4 Fit the drive gear (A1) to the shaft. Install the washer and bolt which retain the gear. Tighte...1989
Fuel system...1990
General information...1990
Fuel priming pump...1991
To remove and to fit Operation 11-1...1991
1 Remove two bolts (A2) and remove fuel priming pump (A1)...1991
1 Inspect the gasket of the fuel priming pump; fit a new gasket if necessary...1991
2 Fit the fuel priming pump (A1) and retain with the two bolts (A2)...1991
Fuel transfer pump...1992
To remove and to fit Operation 11-2...1992
1 Disconnect the fuel pipes from the fuel transfer pump (A2)...1992
2 Use plugs or caps to seal temporarily all openings to prevent contamination of the fuel system...1992
3 Remove the bolts (A1) and withdraw the fuel transfer pump...1992
1 Check the condition of the ‘O’ ring seal on the fuel transfer pump, renew the seal if it is wor...1992
2 Ensure that the ‘O’ ring seal is fitted correctly to the fuel transfer pump. Apply a small amou...1992
3 Fit the fuel transfer pump (A2) and retain with two bolts (A1)...1992
4 Remove the plugs or caps from the fuel pipe openings and connect the fuel pipes...1992
5 Eliminate air from the fuel system, Operation 11-6...1992
To test Operation 11-3...1993
1 Run the pump at 2940 rev/min. The flow at 650 kPa (94 lb/in2) must be 4,5 litres/min (1.0 UK ga...1993
2 Run the pump at 840 rev/min. The flow at 550 kPa (80 lb/in2) must be 3,0 litres/min (0.66 UK ga...1993
3 Run the pump at 100 rev/min with the inlet to the atmosphere for 10 seconds. The pump must main...1993
Drive for the fuel transfer pump...1994
To remove and to fit Operation 11-4...1994
1 Remove the fuel transfer pump (A2), Operation 11-2...1994
2 Remove four bolts and washers (A1) and withdraw the assembly of the pump drive and housing (A3)...1994
3 Remove the three bolts from the housing (B1) and remove the assembly of the bearings and gear (...1994
4 Remove the ‘O’ ring seal (B3) from the housing...1994
5 Inspect all components, renew any which are worn or damaged...1994
1 Fit the assembly of the bearings and gear (B2) into the pump drive housing (B1)...1994
2 Retain the gear and bearings in the housing with the three bolts...1994
3 Fit a new ‘O’ ring seal (B3) to the housing...1994
4 Insert carefully the assembly of the pump drive and pump drive housing into the gear case. Reta...1994
5 Fit the fuel transfer pump, Operation 11-2...1994
Fuel filter header...1995
To remove and to fit Operation 11-5...1995
1 Remove the fuel priming pump (A2), Operation 11-1...1995
2 Disconnect the fuel pipes (A1, A3, A4 and A5). Fit plugs or caps to all openings to prevent con...1995
3 Remove the filter housings and elements from the fuel filter header...1995
4 Remove the bolts which retain the filter header on the crankcase...1995
1 Fit the filter header to the crankcase...1995
2 Remove any plugs or caps and connect the fuel pipes (A1, A3, A4 and A5)...1995
3 Renew the fuel filter elements in the primary and secondary fuel filter canisters. Use the proc...1995
4 Fit the fuel priming pump, Operation 11-1...1995
5 Eliminate air from the fuel system, Operation 11-6...1995
Low pressure fuel system...1996
How to eliminate air from the fuel system Operation 11-6...1996
1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) un...1996
2 Tighten the union (A1). Operate the hand priming pump until a strong pressure is felt on the pu...1996
3 Start the engine...1996
4 If the engine will not start, allow the starter motor to cool for 2 minutes. Repeat steps 1 and...1996
5 Run the engine with no load until it runs smoothly...1996
Cooling system...1998
General information...1998
Cooling system...1999
To inspect Operation 12-1...1999
1 Check the coolant level in the cooling system...1999
2 Check for leaks in the system...1999
3 Ensure that the air flow through the radiator is not restricted. Check for bent fins in the rad...1999
4 Inspect the drive belts for the fan...1999
5 Check for damage to the fan blades...1999
6 Check for air or combustion gas in the cooling system...1999
7 Inspect the filler cap and check the surface which the filler cap seals against. This surface m...1999
Leakage test Operation 12-2...2000
Special tools...2000
Description...2000
Part number...2000
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the ...2000
2 Ensure that the coolant is at the correct level...2000
3 Attach the pressurizing pump, GE50031, to the radiator and apply pressure until the reading on ...2000
4 Check the radiator for leakage...2000
5 Check all connection points and hoses for leakage...2000
Coolant filler cap...2001
To test Operation 12-3...2001
Special tools...2001
Description...2001
Part number...2001
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the ...2001
2 Carefully inspect the filler cap. Check for damage to the seals and to the sealing surface. Exa...2001
3 Check the opening pressure for the filler cap as follows: fit the filler cap to the pressurizin...2001
4 Apply pressure and check the gauge for the exact pressure which opens the filler cap...2001
5 Compare the reading on the gauge with the correct pressure which should open the filler cap, th...2001
6 Renew the filler cap if it is defective...2001
Radiator...2002
To remove and to fit Operation 12-4...2002
1 Drain the coolant into a suitable container...2002
2 Remove the air duct from between the charge air cooler and the air inlet elbow...2002
3 Remove the coolant pipe from between the thermostat housing and the top of the radiator...2002
4 Remove the fan guards...2002
5 Remove the air duct from between the turbocharger and the base of the charge air cooler...2002
6 Remove the coolant pipe from between the coolant pump elbow and the radiator...2002
7 Remove fasteners which retain the radiator to its base frame...2002
1 Fit the radiator to its base frame...2002
2 Fit the coolant pipe between the coolant pump elbow and the radiator...2002
3 Fit the air duct between the turbocharger and the base of the charge air cooler...2002
4 Fit the fan guards...2002
5 Fit the coolant pipe between the thermostat housing and the top of the radiator...2002
6 Fit the air duct between the charge air cooler and the air inlet elbow...2002
7 Fill the radiator with the correct coolant mixture. Refer to the User’s Handbook...2002
8 Run the engine until it reaches the normal temperature of operation and check for leaks...2002
Fan...2003
To remove and to fit Operation 12-5...2003
1 Switch off the engine and disconnect the electrical power supply...2003
2 Remove the fan guards...2003
3 Remove the bolts which retain the fan on the hub and remove the fan...2003
1 Fit the fan to the hub and retain with the six bolts...2003
2 Fit the fan guards...2003
3 Connect the electrical power supply...2003
Fan drive assembly...2004
To remove and to fit Operation 12-6...2004
1 Remove the fan, Operation 12-5...2004
2 Remove the hub (A1)...2004
3 Loosen the adjustment bolts to release the tension on the alternator belt. Remove the belt and ...2004
4 Release the tension on the fan drive belts and remove the belts...2004
5 Remove the two bolts and cap which retain the pulley (A2) and withdraw the pulley complete with...2004
6 Remove the two nuts and two bolts which retain the fan bearing housing (A4) and remove the hous...2004
1 Fit the fan bearing housing (A4)...2004
2 Fit the pulley (A2) and retain with the cap and two bolts. Tighten the bolts to a torque of 24 ...2004
3 Fit the fan drive belts and adjust the tension as given in Operation 12-7...2004
4 Fit the alternator (A3), fit the alternator belt and adjust the tension as given in Operation 1...2004
5 Fit the hub (A1)...2004
6 Fit the fan, Operation 12-5...2004
Fan drive belts...2005
To check and to adjust the tension Operation 12-7...2005
1 Remove the fan guards...2005
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A1). It should b...2005
3 Loosen the lock nuts on the adjustment bolt (A2), loosen the large lock nut on the belt tension...2005
4 Fit the fan guards and run the engine for 15 minutes. Remove the guards and check again the ten...2005
5 For new fan belts, set the tension to 868 N, which is equivalent to 4,0 mm of movement when a f...2005
6 When the correct tension is obtained, fit the fan guards...2005
To renew Operation 12-8...2006
1 Remove the fan, Operation 12-5...2006
2 Loosen the belt tensioner and remove the old belts. Ensure that the grooves of the pulley are f...2006
3 Fit the fan and tighten the bolts securely. Adjust the fan belts to the correct tension, as giv...2006
Engine oil cooler...2007
To remove and to fit Operation 12-9...2007
1 Drain the coolant from the engine...2007
2 Use a tray to collect any oil which may spill from the oil cooler during its removal...2007
3 Make temporary marks on the coolant duct (A2) and the oil cooler (A1) for correct alignment dur...2007
4 Remove the four bolts which retain the oil cooler (B1) on the oil filter header (B3)...2007
5 Withdrawn the oil cooler from the elbow (B2), take care not to damage the seal...2007
6 Remove the ‘O’ ring seal from the elbow (B2)...2007
1 Clean the core tubes of the oil cooler with a 3,81 mm (0.150 in) diameter rod...2007
2 Check the condition of the ‘O’ ring seals used on the oil cooler and the oil filter header. Ren...2007
3 Ensure that the ‘O’ ring seals are fitted to the oil filter header...2007
4 Fit the ‘O’ ring seal over the elbow (B2). Apply clean engine oil on the seal...2007
5 Align the oil cooler with the elbow and slide the oil cooler over the elbow. Fit the four bolts...2007
6 Fit an ‘O’ ring seal to the coolant duct (A2) and fit the duct to the oil cooler. Fit the four ...2007
7 Fill the cooling system with the correct coolant mixture. Refer to the User’s Handbook...2007
8 Check the amount of lubricating oil in the sump. Add lubricating oil of the correct grade, if n...2007
9 Clean away any oil or coolant which has been spilled...2007
Thermostats and thermostat housing...2008
To remove and to fit Operation 12-10...2008
1 Drain the coolant until the level is below the thermostat housing (A1)...2008
2 Disconnect the cable (A3) from the coolant temperature sensor...2008
3 Release the hose clips (A2) and disconnect the pipe and hose from the top of the unit...2008
4 If the thermostats are to be removed, loosen all five bolts of the thermostat housing; then rem...2008
5 Lift carefully the assembly to separate it from the coolant bobbin (A5) at its base...2008
1 Clean thoroughly both parts of the assembly and check the condition of the lip-type seals. Rene...2009
2 Fit the new thermostats. Ensure that the new thermostats are fitted correctly. Fit a new ‘O’ ri...2009
3 Ensure that the mating face on the cylinder head is clean. Fit new seals to the coolant bobbin ...2009
4 Connect the hose to the top of the housing and tighten the hose clip...2009
5 Connect the cable (A3) to the coolant temperature sensor...2009
6 Fill the coolant system to the correct level with the approved coolant mixture...2009
7 Operate the engine until it reaches the normal temperature of operation and check for leaks. St...2009
To test the thermostats Operation 12-11...2010
1 Remove the thermostats from the engine...2010
2 Heat water in a suitable container until the temperature is 98 C (208 F). Stir the water to e...2010
3 Suspend the thermostat in the container of water. The thermostat must be below the surface of t...2010
4 Ensure that the water is maintained at the correct temperature for ten minutes...2010
5 After ten minutes, remove the thermostat. Immediately check the distance that the thermostat ha...2010
Coolant temperature sensor...2011
To test Operation 12-12...2011
Special tools...2011
Description...2011
Part number...2011
1 When the engine is cool, release the coolant filler cap to relieve any pressure...2011
2 Remove one of the two plugs (A1) and install the special thermometer, GE50032. A temperature in...2011
3 Start the engine and run the engine until the temperature reaches the desired range according t...2011
Pointer...2011
position...2011
Test...2011
thermometer C...2011
Test...2011
thermometer F...2011
4 If the temperature sensor is renewed, do not attempt to disconnect the leads from the unit. Dis...2011
Coolant pump...2012
To remove and to fit Operation 12-13...2012
1 Drain the coolant from the engine into a suitable container for storage or disposal...2012
2 Remove the thermostat housing, Operation 12-10...2012
3 Remove the oil cooler, Operation 12-9...2012
4 Remove four bolts (A1) and the elbow (A2)...2012
5 Check the condition of the ‘O’ ring seal (B1), discard the seal if it is worn or damaged. Remov...2012
1 Fit the coolant pump to the gear case, ensure that the gear engages correctly. Tighten the bolts...2012
2 If necessary, fit a new ‘O’ ring seal (B1). Fit the elbow (A2) and retain with four bolts (A1)...2012
3 Fit the oil cooler, Operation 12-9...2012
4 Fit the thermostat housing, Operation 12-10...2012
5 Fill the coolant system to the correct level with the specified coolant mixture. Refer to the U...2012
To dismantle and to assemble Operation 12-14...2013
1 Remove the bolt (A15) and washer (A14). Use a suitable puller to remove the impeller (A11) from...2013
2 Remove the spring and seal (A13) from the shaft...2013
3 Remove the four bolts (A6) from the retainer (A7) and remove the ‘O’ ring seal (A9) from the ho...2013
4 Remove the gear and shaft assembly (A8). Remove the bolt (A4) and retainers (A3 and A7) from th...2013
5 Use a press to remove the shaft (A16) from the gear. Remove the bearing (A1), the spacer if fit...2013
6 Remove the lip-type seal (A12) from the housing...2013
1 Ensure that the shaft and the seal counter bore in the pump housing are clean...2014
2 Fit the bearing (A1), the spacer if relevant, and the second bearing (A2) to the shaft (A16)...2014
3 Fit the retainer (A7) and gear (A8) to the shaft assembly. Fit the second retainer (A3) and the...2014
4 Fit a new lip-type seal (A12) into the housing (A10). The seal must be fitted with the lip towa...2014
5 Fit a new ‘O’ ring seal (A9) to the housing...2014
6 Install the gear and shaft assembly in the housing. Fit the bolts (A6) which hold the retainer ...2014
7 Separate the spring from the seal assembly (A13). Use hand pressure to install the seal on the ...2014
8 Fit the impeller (A11) to the shaft and retain with the washer (A14) and bolt (A15). Tighten th...2014
9 Fit the coolant pump, Operation 12-13...2014
To test the pressure of the coolant pump Operation 12-15...2015
Special tools...2015
Description...2015
Part number...2015
1 To check that the coolant pump is operating correctly, the outlet pressure can be measured...2015
2 Remove the plug (A1) from the coolant manifold and connect the pressure gauge, GE50033, to the ...2015
3 Start the engine and run the engine until the normal temperature of operation is obtained...2015
4 Make a note of the reading on the pressure gauge. The pressure supplied by the coolant pump sho...2015
Flywheel and housing...2016
General information...2016
Flywheel...2017
To remove and to fit Operation 13-1...2017
1 Remove two of the flywheel bolts from horizontally opposite sides of the flywheel and insert tw...2017
2 Remove the bolts which remain and withdraw the flywheel from the crankshaft. Fit a suitable sli...2017
3 Remove the flywheel and remove the guide studs...2017
4 Remove the gear ring from the flywheel if necessary...2017
1 If the gear ring has been removed, heat the ring in an oven to a maximum temperature of 315 C ...2017
2 Fit suitable guide studs to bolt holes at horizontally opposite sides of the flywheel. Ensure t...2017
3 Attach a sling to the flywheel and use a hoist to locate the flywheel on the guide studs. Ensur...2017
4 Remove the sling and slide the flywheel up to the crankshaft...2017
5 Apply clean engine oil to the threads of the bolts which retain the flywheel and fit 10 of the ...2017
Flywheel housing...2018
To remove and to fit Operation 13-2...2018
Consumable products...2018
Description...2018
Part number...2018
1 Remove the flywheel, Operation 13-1...2018
2 Remove the crankshaft rear seal and wear sleeve, Operation 5-3...2018
3 Remove the starter motor, Operation 14-1...2018
4 Remove the sump, Operation 10-3...2018
5 Use a suitable hoist to support the flywheel housing and remove the bolts (A1 to A24) which ret...2018
6 Remove the flywheel housing from the dowels in the crankcase. The weight of the flywheel housin...2018
1 Clean thoroughly the contact surfaces of the crankcase and flywheel housing...2019
2 Fit the two dowels (B2 and B3) if they have been removed from the crankcase. They must protrude...2019
3 Apply a bead of liquid gasket, CH10879, to the area shown (B1)...2019
4 Attach a suitable hoist and fit the flywheel housing to the crankcase. Fit the bolts which reta...2019
5 Tighten the flywheel housing bolts as follows:...2019
6 Fit the sump, Operation 10-3...2019
7 Fit the starter motor, Operation 14-1...2019
8 Fit a new crankshaft rear seal and wear sleeve, Operation 5-3...2019
9 Fit the flywheel, Operation 13-1...2019
Electrical equipment...2020
General information...2020
Starter motor...2021
To remove and to fit Operation 14-1...2021
1 Disconnect the batteries before any service work is attempted...2021
2 Disconnect the wiring loom from the starter motor assembly (A2)...2021
3 Fasten a hoist to the starter motor. Remove the three bolts (A1) which retain the starter motor...2021
1 Use a hoist to support the starter motor. Fit the starter motor to the flywheel housing. Retain...2021
2 Connect the wiring loom to the starter motor. If the engine earth strap is connected to the sta...2021
3 Connect the batteries...2021
Alternator...2022
To remove and to fit Operation 14-2...2022
1 Disconnect the batteries before any service work is attempted...2022
2 Remove the access panel in the fan guard...2022
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley ...2022
4 Disconnect the wiring loom from the alternator...2022
5 Remove the bolts (A3 and A4) and remove the alternator...2022
1 Fit the alternator and retain with the pivot bolt (A3) and the adjustment link bolt (A4). Do no...2022
2 Fit the alternator drive belt over the alternator pulley and set the tension as given in Operat...2022
3 Connect the wiring loom to the alternator...2022
4 Fit the access panel to the fan guard...2022
5 Connect the batteries...2022
To check and to adjust the tension of the alternator belt Operation 14-3...2023
1 Remove the access panel in the fan guard and proceed as follows...2023
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A5). It should b...2023
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley ...2023
4 Fit the access panel to the fan guard and run the engine for 15 minutes. Remove the access pane...2023
5 If a new alternator belt is fitted, set the tension to 400 N, which is equivalent to 2,5 mm of ...2023
6 When the correct tension is obtained, fit the access panel to the fan guard...2023
To renew the alternator belt Operation 14-4...2024
1 Remove the fan, Operation 12-5...2024
2 Loosen the adjustment bolts to release the tension on the alternator belt and remove the old be...2024
3 Fit the fan, Operation 12-5...2024
4 Adjust the alternator belt to the correct tension, Operation 14-3...2024
Auxiliary equipment...2026
General information...2026
Oil sample valve...2026
Special tools...2028
List of special tools...2028
Tool number...2028
Description...2028
Illustration...2028
TSD3453E3 - Diagnostic Manual (2800 Series_Models 2806C-E16 & 2806C-E18 (6 cylinder turbocharged diesel engine))...2036
TSD3454E2 - User's Handbook (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications))...2192
TSD3455E1 - Workshop Manual (2300 Series_Model 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications))...2252
Perkins 2300 Series...2252
Model 2306C-E14...2252
Workshop manual...2252
6 cylinder turbocharged diesel engines for industrial applications...2252
Chapters...2253
1 General information...2253
2 Specifications...2253
3 Cylinder head assembly...2253
4 Piston and connecting rod assemblies...2253
5 Crankshaft assembly...2253
6 Gear case and drive assembly...2253
7 Crankcase and cylinder liners...2253
8 Engine timing and electronic controls...2253
9 Aspiration system...2253
10 Lubrication system...2253
11 Fuel system...2253
12 Cooling system...2253
13 Flywheel and housing...2253
14 Electrical equipment...2253
15 Auxiliary equipment...2253
16 Special tools...2253
Publication TSD3455E, Issue 1...2252
© Proprietary information of Perkins Engines Company Limited, all rights reserved...2252
The information is correct at the time of print...2252
Published in September 2002 by Technical Publications,...2252
Perkins Engines Company Limited, Shrewsbury SY1 3NX, England...2252
Contents...2254
1 General information...2254
Introduction 1...2254
Safety precautions 2...2254
Viton seals 4...2254
Welding 4...2254
Environmental protection 4...2254
Engine views 5...2254
Engine identification 6...2254
Engine lift equipment 6...2254
2 Specifications...2254
Basic engine data - 2306 engine 7...2254
Basic engine data - 2806 engine 7...2254
Rocker assemblies 8...2254
Valves 9...2254
Valve guides 10...2254
Valve springs 10...2254
Valve seat inserts 11...2254
Cylinder head 12...2255
Camshaft and bearings 12...2255
Pistons and connecting rods - 2306 engine 13...2255
Pistons and connecting rods - 2806 engine 14...2255
Crankshaft, main bearings and flywheel 15...2255
Crankshaft damper 15...2255
Crankcase and cylinder liners 16...2255
Lubricating oil pump 18...2255
Coolant pump 19...2255
Recommended torque figures 20...2255
3 Cylinder head assembly...2255
General information 27...2255
4 Pistons and connecting rod assemblies...2256
General information 57...2256
5 Crankshaft assembly...2256
General information 63...2256
6 Gear case and drive assembly...2256
General information 73...2256
7 Crankcase and cylinder liners...2257
General information 81...2257
8 Engine timing and electronic controls...2257
General information 87...2257
9 Aspiration system...2257
General information 91...2257
10 Lubrication system...2258
General information 95...2258
11 Fuel system...2258
General information 103...2258
12 Cooling system...2258
General information 111...2258
13 Flywheel and housing...2259
General information 129...2259
14 Electrical equipment...2260
General information 133...2260
15 Auxiliary equipment...2260
General information 139...2260
Oil sample valve 139...2260
16 Special tools...2260
List of special tools 141...2260
General information...2262
Introduction...2262
Safety precautions...2263
Viton seals...2265
Welding...2265
Environmental protection...2265
Engine views...2266
Engine identification...2267
Engine lift equipment...2267
Specifications...2268
Basic engine data - 2306 engine...2268
Basic engine data - 2806 engine...2268
Rocker assemblies...2269
Valves...2270
Valve guides...2271
Valve springs...2271
Valve seat inserts...2272
Cylinder head...2273
Camshaft and bearings...2273
Pistons and connecting rods - 2306 engine...2274
Pistons and connecting rods - 2806 engine...2275
Crankshaft, main bearings and flywheel...2276
Crankshaft damper...2276
Crankcase and cylinder liners...2277
Lubricating oil pump...2279
Coolant pump...2280
Recommended torque figures...2281
Standard torque figures for metric fasteners...2281
Metric nuts and bolts...2281
Thread size...2281
metric...2281
Standard torque...2281
Metric taperlock studs...2281
Thread size...2281
metric...2281
Standard torque...2281
Standard torque figures for imperial fasteners...2282
Imperial nuts and bolts...2282
Thread size...2282
inches...2282
Standard torque...2282
Imperial taperlock studs...2282
Thread size...2282
inches...2282
Standard torque...2282
Standard torque figures for ‘O’ ring face seal fittings and 37 degree flared fittings...2283
Torque figures for ferrous straight thread ‘O’ ring fittings when connected to ferrous materials...2283
Outside diameter of nominal tube...2283
Thread size...2283
Inches...2283
Standard...2283
torque...2283
‘O’ ring face seal fittings...2284
Torque figures for ferrous straight thread ‘O’ ring fittings (B)...2284
Thread size...2284
inches...2284
Standards torque...2284
Torque figures for flared and ‘O’ ring fittings...2285
Nuts for 37 degree flared fittings...2285
Outside diameter of nominal tube...2285
Thread size...2285
Inches...2285
Standard...2285
torque...2285
45 degree flared and 45 degree inverted flare fittings...2286
45 degree flared and 45 degree inverted flare fittings...2286
Outside diameter of nominal tube...2286
Thread size...2286
Inches...2286
Standard...2286
torque...2286
Tapered pipe thread fittings...2286
Tapered pipe thread fittings...2286
Thread size...2286
Inches...2286
Standard torque...2286
Threads with pipe sealant (CV60891)...2286
Threads without pipe sealant...2286
Torque figures for standard hose clamps of the worm drive band type...2287
Width of clamp...2287
Torque figure for initial...2287
installation on a new hose...2287
Torque figures for constant torque hose clamps...2287
Cylinder head assembly...2288
General information...2288
Rocker cover...2289
To remove and to fit Operation 3-1...2289
1 Disconnect the wiring harness at the socket on the rocker cover (A1)...2289
2 Disconnect and remove the engine breather pipe (A2)...2289
3 Loosen fully the bolts which retain the rocker cover, but do not remove the bolts from the asse...2289
4 Remove the rocker cover...2289
1 Inspect the seal of the rocker cover and renew if worn of damaged...2289
2 Fit the rocker cover, complete with seal and bolts. Tighten the bolts to a torque of 20 Nm (15 ...2289
3 Fit the engine breather pipe (A2)...2289
4 Connect the wiring harness. Ensure that the wiring harness is fully engaged with the connector...2289
Rocker lever and rocker shaft assemblies...2290
To remove and to fit Operation 3-2...2290
1 Remove the rocker cover, Operation 3-1...2290
2 The valve rocker levers (A1) and the unit injector rocker levers (A2) can move on the shaft (A6...2290
3 Remove the four bolts (A5)...2290
4 Remove the shaft (A6), valve rocker levers (A1) and unit injector rocker levers (A2) as a unit...2290
5 Repeat steps 1 and 2 for the rocker shaft assemblies which remain...2290
1 Loosen the adjustment screws (A3 and A4) of each of the rocker levers which have been removed. ...2290
2 Set the tappet clearances, Operation 3-4...2290
3 Check/adjust the unit injectors, Operation 3-13...2290
4 Fit the rocker cover, Operation 3-1...2290
To dismantle and to assemble Operation 3-3...2291
1 Slide the valve rocker levers (A3) and the unit injector rocker levers (A4) from the shaft (A7)...2291
2 Remove the button (A1) from the adjustment screw (A2) in the valve rocker lever (A3)...2291
3 Remove the button (A6) from the adjustment screw (A5) in the unit injector rocker lever (A4)...2291
4 Repeat steps 1 to 3 for the rocker lever assemblies which remain...2291
1 Install new ‘O’ ring seals in the buttons (A1)...2292
2 Install new ‘O’ ring seals in the buttons (A6)...2292
3 To fit the ‘O’ ring seals and buttons to the valve rocker levers, proceed as follows:...2292
4 To fit the ‘O’ ring seals and buttons to the unit injector rocker levers, proceed as follows:...2292
5 Repeat steps 3 and 4 for the rocker levers which remain...2292
6 Fit the assembled rocker levers to the shafts (A7). Ensure that they are fitted to their origin...2292
How to check/adjust the tappet clearances Operation 3-4...2293
Special tools...2293
Tappet clearances...2293
Description...2293
Part number...2293
Inlet...2293
Exhaust...2293
1 Remove the rocker cover, Operation 3-1...2293
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...2293
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2293
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2293
5 Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the pisto...2294
6 Before each set of tappet clearances is adjusted, ensure that the roller of the rocker lever is...2294
7 Use a set of feeler gauges, inserted at the position shown (B3) between the valve bridge piece ...2294
8 After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a ...2295
9 Withdraw the timing bolt and rotate the flywheel by 360 degrees so that the number 6 piston is ...2295
10 Check the tappet clearances for the inlet valves (C1) on cylinders 3, 5 and 6. Adjust the clea...2295
11 After each unit has been adjusted, tighten the lock nut of the adjustment screw to a torque of...2295
12 Check again the tappet clearances for all six cylinders...2295
13 Fit the rocker cover. Remove the engine turning tool and the timing bolt and fit the cover to ...2295
Cylinder head assembly...2296
To remove and to fit Operation 3-5...2296
Special tools...2296
Consumable products...2296
Description...2296
Part number...2296
Description...2296
Part number...2296
1 Remove the thermostat housing, Operation 12-10...2296
2 Remove the exhaust manifold, Operation 9-1...2296
3 Remove the rocker lever and rocker shaft assemblies, Operation 3-2...2296
4 Remove the electronic unit injectors, Operation 3-12...2296
5 Remove the gear case cover, Operation 6-1...2296
6 Disconnect the cable and remove the timing sensor from the cylinder head...2296
7 Remove the support bracket which is fitted between the gear case and the cylinder head...2296
8 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bol...2296
9 Disconnect the fuel lines from the front and rear of the cylinder head. Fit temporary covers to...2296
10 Remove the cylinder head bolts; use the special socket, GE50020...2296
11 Fit the lifting bracket (A1), VP12712, to the cylinder head and attach a suitable hoist. Remov...2296
12 Remove the cylinder head gasket (B4)...2297
13 Remove the ‘O’ ring seal from the oil transfer tube (B6) and remove the 24 coolant seals (B3)...2297
14 Remove the seal (B2)...2297
15 Remove the spacer plate (B5) and discard the spacer plate gasket...2297
16 Remove the second ‘O’ ring seal from the oil transfer tube (B6)...2297
1 If the oil transfer tube (B6) has been removed, apply retaining compound, 21820 638, and insert...2298
2 If the rear dowel has been removed, apply retaining compound, 21820 638, and insert it in the c...2298
3 If the front dowel, close to the oil transfer tube, has been removed, it must be fitted in a dr...2298
4 Fit suitable guide studs (B1) to the cylinder block. Fit a new spacer plate gasket over the dow...2298
5 Fit a new ‘O’ ring seal to the oil transfer tube (B6)...2298
6 Fit the spacer plate (B5) and fit the second ‘O’ ring seal to the oil transfer tube (B6). Fit t...2298
7 Check, and if necessary adjust, the protrusion of the cylinder liners, Operation 7-3...2298
8 Fit a new cylinder head gasket (B4) to the spacer plate...2298
9 Fasten a hoist to the cylinder head, use the lifting bracket VP12712, and lower the cylinder he...2299
10 Apply special lubricant, CV60895, to the washers, the threads and under the heads of the bolts...2299
11 Fit the camshaft gear. Check and, if necessary, adjust the backlash between the camshaft gear ...2299
12 Fit the gear case cover, Operation 6-1...2299
13 Fit the support bracket between the cylinder head and the gear case...2299
14 Fit the electronic unit injectors, Operation 3-12...2299
15 Fit the rocker lever and shaft assemblies, Operation 3-2...2299
16 Fit the exhaust manifold, Operation 9-1...2299
17 Fit the thermostat housing, Operation 12-10...2299
18 Remove the covers from the fuel lines and from the fuel line ports on the cylinder head. Conne...2299
19 Fit the timing sensor and connect the cable...2299
Valve springs...2300
To remove and to fit Operation 3-6...2300
Special tools...2300
Description...2300
Part number...2300
1 Remove the rocker lever and rocker shaft assemblies, Operation 3-2...2300
2 Remove the electronic unit injectors, Operation 3-12...2300
3 Set the piston for the relevant valve spring assembly to the top of its compression stroke...2300
4 Use the hold-down clamp from the electronic unit injector to secure the valve spring compressor...2300
5 Insert the stud and base of the valve spring compressor into the bore of the injector sleeve. U...2300
6 Tighten the nut until the collets are loose on the valves...2300
7 Remove two collets from each valve...2300
8 Loosen slowly, then remove the nut, washer, thrust bearing and plate...2300
9 Remove the rotocoils, valve springs and washers from each valve...2300
10 Inspect the valve springs, refer to Chapter 2, Specifications for the correct dimensions and s...2300
11 Repeat steps 3 to 10 for the other valve spring assemblies which are to be removed...2300
1 Apply clean engine oil to the relevant valve stems...2301
2 Fit the washer, valve spring and rotocoil to each valve...2301
3 Use the valve spring compressor, GE50026, to compress the valve springs...2301
4 Fit two collets to each valve...2301
5 Loosen slowly and then remove the nut (A2) and plate (A1) of the valve spring compressor. Remov...2301
6 Tap lightly each valve with a soft hammer to ensure that the collets are seated correctly...2301
7 Fit the electronic unit injectors, Operation 3-12...2301
8 Fit the rocker lever and rocker shaft assemblies, Operation 3-2...2301
Valves...2302
To remove and to fit Operation 3-7...2302
Special tools...2302
Description...2302
Part number...2302
1 Remove the cylinder head, Operation 3-5...2302
2 Put the cylinder head, flame face down, on a bench with a soft surface and release the valves b...2302
3 Withdraw the valves from the cylinder head...2302
4 Repeat the procedure for all valves which are to be removed...2302
1 Apply clean engine oil to the stems of the valves. Fit the valves to their original positions i...2302
2 Use the special tool, GE50026, and the procedure given in Operation 3-6, to install the valve s...2302
3 Fit the cylinder head, Operation 3-5...2302
Valve seals...2303
To renew Operation 3-8...2303
Special tools...2303
Description...2303
Part number...2303
1 Remove the relevant valve spring assembly, Operation 3-6...2303
2 Remove the valve seal from the valve and valve guide...2303
3 Apply a thin film of clean engine oil to the new valve seal and slide the seal over the valve s...2303
4 If the valve seal is to be fitted to a valve guide with the valve removed, fit the seal to the ...2303
5 Use the special tool, GE50027, and hand pressure only to push the valve seal into its position ...2303
6 Withdraw the tool and fit the valve spring assembly, Operation 3-6...2303
Valve guides...2304
To remove and to fit Operation 3-9...2304
Special tools...2304
Description...2304
Part number...2304
1 Remove the cylinder head, Operation 3-5...2304
2 Remove the valves, Operation 3-7...2304
3 Use the special tool (A1), GE50043, and a hammer to drive the valve guide (A2) from the cylinde...2304
1 Apply clean engine oil to the outside diameter of the new valve guides...2305
2 Use the special tool (B1), GE50043, together with the sleeve (B2), GE50044, to install the valv...2305
3 When a new valve guide has been fitted, check that there is full contact between the valve and ...2305
4 Fit the valves, Operation 3-7...2305
5 Fit the cylinder head, Operation 3-5...2305
Camshaft...2306
To remove and to fit Operation 3-10...2306
Special tools...2306
Consumable products...2306
Description...2306
Part number...2306
Description...2306
Part number...2306
1 Remove the radiator, Operation 12-4...2306
2 Remove the fan, Operation 12-5...2306
3 Remove the gear case cover, Operation 6-1...2306
4 Remove the rocker cover, Operation 3-1...2306
5 Remove the rocker lever and shaft assemblies, Operation 3-2...2306
6 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...2306
7 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2306
8 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2307
9 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case...2307
10 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bo...2307
11 Attach a hoist to the camshaft gear and withdraw the gear from the camshaft. Remove the guide ...2307
12 Remove three bolts and withdraw the thrust plate, the adaptor plate and the seal assembly...2307
13 Use the bolts of the rocker shaft to retain the cradle tool (B1), GE50018, at the position sho...2307
14 Remove the rear cover (C1), complete with seal (C3)...2308
15 Fit the camshaft guide (D1), GE50017, to the gear case. Do not tighten the bolts for the guide...2308
16 Install a pilot tool, GE50015, into the threaded hole at the rear end of the camshaft. Then at...2308
17 Withdraw the camshaft until it enters the bore of the camshaft guide. Tighten the bolts which ...2308
18 Use the lifting hooks, GE50025, to move the camshaft toward the front of the engine...2308
19 Withdraw the camshaft from the cylinder head just enough for a strap and hoist to be attached...2308
1 Fit the two pilot tools, GE50015, to the rear end of the camshaft. Ensure that the camshaft and...2309
2 Fit the camshaft guide (E1), GE50017, to the gear case cover, but do not tighten the bolts fully...2309
3 Insert the alignment sleeve (E2), GE50016, through the camshaft guide (E1) and into the camshaf...2309
4 Fit the cradle tool (F1), GE50018, at the position shown (F)...2309
5 Use a suitable strap and hoist to support the camshaft. Insert the camshaft through the guide a...2309
6 Remove the strap and hoist. Rotate the camshaft during installation. Do not allow the end of th...2309
7 Remove the pilot tools and push the camshaft fully into its bore...2309
8 Inspect the seal (G3) and renew if necessary. Fit the rear cover (G1), complete with seal (G3)...2309
9 Remove the cradle tool and the camshaft guide...2310
10 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubric...2310
11 Fit the guide stud, GE50019, to the camshaft...2310
12 Fit the camshaft gear; align the hole in the gear with the dowel pin on the adapter plate. If ...2310
13 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tig...2310
14 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the...2310
15 Fit the gear case cover, Operation 6-1...2310
16 Remove the timing bolt from the flywheel and fit the cover and plug...2310
17 Install the rocker lever and shaft assemblies, Operation 3-2...2310
How to set the backlash for the camshaft gear Operation 3-11...2311
1 Remove the main idler gear (A3). Hold the camshaft gear stationary and use a dial test indicato...2311
2 Fit the main idler gear (A3), hold the main idler gear stationary and measure the backlash on t...2311
3 To adjust the backlash, remove the three bolts and thrust plate which retain the adjustable idl...2311
4 Fit the idler gear. Retain with the thrust plate and three bolts. Check again the backlash betw...2311
5 When the correct backlash settings have been obtained, remove the adjustable idler gear and pro...2311
Electronic injector units...2312
To remove and to fit Operation 3-12...2312
Special tools...2312
Description...2312
Part number...2312
Description...2312
Part number...2312
1 Remove the relevant rocker shaft assembly, Operation 3-2...2312
2 Loosen the two nuts and remove the electrical connector from the injector unit...2312
3 Mark the valve bridge pieces to assist during assembly, then remove them...2312
4 Remove the bolt (A2) from the spacer and clamp which retain the injector unit and use the speci...2312
5 Remove the injector unit, together with the spacer and clamp...2312
6 Use the vacuum pump, GE50028, together with the tube, GE50030, and bottle, GE50029, to extract ...2312
1 Clean thoroughly the bore of the injector sleeve and cylinder head. Use the special brushes (GE...2313
2 Check the condition of the ‘O’ ring seals (B1 and B2); renew the seals if they are worn or dama...2313
3 Fit the injector unit to the cylinder head. Fit the clamp, spacer and retaining bolt. Tighten t...2313
4 Fit the bridge pieces...2313
5 Attach the electrical connector to the injector unit and retain with the two nuts. Tighten the ...2313
6 Fit the rocker shaft assembly, Operation 3-2...2313
To check and to adjust Operation 3-13...2314
Special tools...2314
Description...2314
Part number...2314
1 With the rocker covers removed, set the number 1 piston to TDC (top dead centre) on its compres...2314
2 Use the fuel injector setting gauge, CH11149, to obtain the correct height for the fuel injecto...2314
3 Remove the timing bolt from the flywheel housing and rotate the flywheel by 360 degrees in the ...2314
4 Check/adjust the height dimensions for the fuel injectors of cylinders 1, 2 and 4 as given in s...2314
Injector sleeves...2315
To remove and to fit Operation 3-14...2315
Special tools...2315
Description...2315
Part number...2315
Description...2315
Part number...2315
1 Remove the rocker shaft assemblies, Operation 3-2...2315
2 Remove the electronic injector units, Operation 3-12...2315
3 Mark the bridge pieces and make a note of their position to assist during assembly, then remove...2315
4 Fit the puller stud from the special tool, GE50021, into the injector sleeve as shown (A). Fit ...2315
5 Remove the ‘O’ ring seals from the injector sleeve. Check the condition of the injector sleeve ...2315
6 Repeat steps 1 to 5 for the injector sleeves which remain...2315
1 Use the brushes, special tool numbers: GE50023, GE50024 and GE50022, to clean thoroughly the bo...2316
2 Fit new ‘O’ ring seals to the injector sleeve...2316
3 Fit the stud from the special tool into the threads of the injector sleeve...2316
4 Apply CV60889 anti-seize compound to the ‘O’ ring seals and to the large diameter (B1) off the ...2316
5 Apply CV60893 retaining compound to the small diameter (B2) off the injector sleeve...2316
6 Using the stud, insert the injector sleeve into its bore in the cylinder head. Take care to pre...2316
7 Fit the driver tool over the stud and tap lightly with a hammer to ensure that the injector sle...2316
8 Use a clean cloth to remove any retaining or anti-seize compound from the bores of the cylinder...2316
9 Fit the electronic injector units, Operation 3-12...2316
10 Fit the rocker shaft assemblies, Operation 3-2...2316
Pistons and connecting rod assemblies...2318
General information...2318
Pistons and connecting rod assemblies...2319
To remove and to fit Operation 4-1...2319
Special tools...2319
Consumable products...2319
Description...2319
Part number...2319
Description...2319
Part number...2319
1 Remove the cylinder head assembly, Operation 3-5...2319
2 Remove the oil pump, Operation 10-4...2319
3 Remove the stiffener plate from the base of the crankcase...2319
4 Remove the carbon ridge from the top inside surface of the cylinder liners...2319
5 Turn the crankshaft until two pistons are at bottom centre...2319
6 Remove the bolts (A1) and the bearing caps. Push the connecting rods and pistons up until the r...2319
7 Withdraw carefully the pistons and connecting rods from the cylinder liners. Store the bearing ...2319
8 Repeat steps 3 to 6 for the remainder of the pistons and connecting rods...2319
1 Apply clean engine oil to the piston rings, the connecting rod bearings and the cylinder liners...2320
2 Ensure that the piston ring gaps are set at 120 degree intervals to each other...2320
3 Use the special tool (B1), GE50003 for 2806 engines or GE50045 for 2306 engines, to install the...2320
4 Fit the bearing cap to the connecting rod. The cap must be fitted with its number on the same s...2320
5 Apply anti-seize compound, CV60890, to the bolt threads. Install the bolts and bearing cap. Tig...2320
6 Repeat steps 1 to 4 for the remainder of the pistons and connecting rods...2320
7 Fit the stiffener plate to the base of the crankcase...2320
8 Fit the oil pump, Operation 10-4...2320
9 Fit the cylinder head assembly, Operation 3-5...2320
To dismantle and assemble Operation 4-2...2321
1 Remove the pistons and connecting rod assemblies, Operation 4-1...2321
2 Remove the big-end bearing shells (A5) from the connecting rod (A4) and connecting rod cap. If ...2321
3 Remove the circlips (A1)...2321
4 Remove the gudgeon pin (A2) and separate the connecting rod and the piston crown from the piston...2321
5 Remove carefully the piston rings (A3) from the piston crown and clean the piston ring grooves ...2321
1 Check the gaps between the ends of the piston rings when the rings are inserted in a new liner...2322
2 Fit the spring of the oil control ring to its groove in the piston crown...2322
3 Use a suitable piston ring expander to fit the oil control ring to its groove in the piston crown...2322
4 Fit the second (intermediate) piston ring with the side that has the identification "UP-2" towa...2322
5 Fit the first (top) piston ring with the side that has the identification "UP-1" toward the top...2322
6 When all three piston rings have been fitted, adjust the position of the piston ring gaps so th...2322
7 Fit the piston crown into the piston skirt and insert the connecting rod. Apply clean engine oi...2322
8 Fit the big-end bearings to the connecting rod (A4) and connecting rod cap. If the original bea...2322
9 Fit the pistons and connecting rod assemblies, Operation 4-1...2322
Piston cooling jets...2323
To remove and to fit Operation 4-3...2323
Special tools...2323
Description...2323
Part number...2323
1 Remove oil pump, Operation 10-4...2323
2 Use the engine turning tool, CH11148, to turn the crankshaft in a clockwise direction (as seen ...2323
3 Remove the bolt which retains the cooling jet and remove the cooling jet from the engine...2323
4 Repeat steps 2 and 3 for the cooling jets which remain...2323
1 Before a piston cooling jet is fitted to the engine, use the jet alignment tool, GE50004, to en...2323
2 Carefully fit the piston cooling jets to the engine, ensure that the nozzles of the cooling jet...2323
3 Fit the oil pump, Operation 10-4...2323
Crankshaft assembly...2324
General information...2324
Crankshaft...2325
To remove and to fit Operation 5-1...2325
Consumable products...2325
Description...2325
Part number...2325
1 Remove the gear case cover, Operation 6-1...2325
2 Remove the flywheel housing, Operation 13-2...2325
3 Remove the pistons and connecting rod assemblies, Operation 4-1...2325
4 Remove the crankshaft rear seal and wear sleeve, Operation 5-3...2325
5 Remove the crankshaft front seal and wear sleeve, Operation 5-2...2325
6 Remove the bolts (A1) which retain the main bearing caps in the crankcase and remove the bearin...2325
7 Fit one of the bolts from the front pulley to each end of the crankshaft. Fasten a hoist to the...2325
1 Clean the crankcase and the main bearing caps thoroughly. Apply clean engine oil to the main be...2326
2 Install one of the bolts from the front pulley in each end of the crankshaft, fasten a suitable...2326
3 Fit the thrust bearings for the centre main bearing. Ensure that the bearings are fitted with t...2326
4 Fit the main bearings to the bearing caps...2326
5 Ensure that the tabs on the back of the bearing shells fit into the tab slots of the bearing ca...2326
6 Apply anti-seize compound, CV60890, to the bolts and install the main bearing caps and bolts...2326
7 Begin at the tab end of the bearing cap first, tighten each bearing cap bolt to a torque of 260...2326
8 Use a dial test indicator (DTI) to check the end-float of the crankshaft. Ensure that the point...2326
9 Fit the crankshaft front seal and wear sleeve, Operation 5-2...2326
10 Fit the crankshaft rear seal and wear sleeve, Operation 5-3...2326
11 Fit the pistons and connecting rod assemblies, Operation 4-1...2326
12 Fit the flywheel housing, Operation 13-2...2326
13 Fit the gear case cover, Operation 6-1...2326
Crankshaft front seal and wear sleeve...2327
To renew Operation 5-2...2327
Special tools...2327
Consumable products...2327
Description...2327
Part number...2327
Description...2327
Part number...2327
1 Remove the vibration damper, Operation 5-4...2327
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapp...2327
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the ...2327
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With ...2327
5 Remove the distorter tool, the protection ring and the wear sleeve...2327
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure prime...2328
2 Use the bolts (C3), GE50009, to install the guide, GE50008, on the crankshaft...2328
3 Fit the wear sleeve and seal (C4) as a unit onto the locator, GE50008...2328
4 Fit the installer (C2), GE50012, onto the locator...2328
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the ins...2328
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in ...2328
7 Remove all of the tools from the crankshaft...2328
8 Fit the vibration damper, Operation 5-4...2328
Crankshaft rear seal and wear sleeve...2329
To renew Operation 5-3...2329
Special tools...2329
Consumable products...2329
Description...2329
Part number...2329
Description...2329
Part number...2329
1 Remove the flywheel, Operation 13-1...2329
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapp...2329
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the ...2329
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With ...2329
5 Remove the distorter tool, the protection ring and the wear sleeve...2329
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure prime...2330
2 Use the bolts (C4), GE50009, to install the guide, GE50008, on the crankshaft...2330
3 Fit the wear sleeve and seal (C3) as a unit onto the locator, GE50008...2330
4 Fit the installer (C2), GE50012, onto the locator...2330
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the ins...2330
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in ...2330
7 Remove all of the tools from the crankshaft...2330
8 Fit the flywheel, Operation 13-1...2330
Crankshaft vibration damper...2331
To remove and to fit Operation 5-4...2331
1 Remove the fan guards...2331
2 Slacken the tension on the fan drive belts, then remove the belts from the crankshaft pulley (A1)...2331
3 Attach a strap and a suitable lifting device to the vibration damper (A2). Remove the six bolts...2331
4 Remove damper and adapter. The weight of the vibration damper is approximately 25 kg (55 lb)...2331
1 Attach a strap and a suitable lifting device to the vibration damper (A2). Use a 5/8 -18 x 6 in...2332
2 Fit the crankshaft pulley (A1). Apply clean engine oil to the threads of the bolts and install ...2332
3 Remove the guide stud and install the final bolt and washer. Tighten the bolts to a torque of 2...2332
4 Fit the fan belts and adjust the tension as given in Operation 12-7...2332
5 Fit the fan guards...2332
Gear case and drive assembly...2334
General information...2334
Gear case cover...2335
To remove and to fit Operation 6-1...2335
1 Remove the radiator, Operation 12-4...2335
2 Remove the fan, Operation 12-5...2335
3 Loosen the bolts which retain the gear case cover. Do not remove the bolts from the assembly, a...2335
4 Remove the gear case cover...2335
1 Examine the seal and renew if necessary, clean the contact surfaces of the seal and the gear case...2335
2 Fit the gear case cover and tighten the bolts, in the sequence shown (A), to a torque of 20 Nm ...2335
3 Fit the fan, Operation 12-5...2335
4 Fit the radiator, Operation 12-4...2335
Timing gears...2336
To remove and to fit Operation 6-2...2336
Special tools...2336
Consumable products...2336
Description...2336
Part number...2336
Description...2336
Part number...2336
1 Remove the gear case cover, Operation 6-1, and set the engine to the correct timing position fo...2336
2 Remove the top bolt (A1) from the cover (A2) on the flywheel housing and loosen the other cover...2336
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2336
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2336
5 Remove the rocker lever and rocker shaft assemblies, Operation 3-2. If the camshaft gear (C2) i...2337
6 Remove the camshaft gear (C2), if relevant. Use the guide stud, GE50019. If the gear case is to...2337
7 Remove the three bolts and the thrust plate (C3) and remove the adjustable idler. Discard the b...2337
8 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...2337
9 Remove the three bolts and the thrust plate (C4) and remove the main idler. Discard the bolts...2337
10 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...2337
11 Remove the four bolts and the thrust plate (C1) and withdraw the compound idler. Discard the b...2337
12 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...2337
13 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaf...2337
14 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is w...2337
15 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diamet...2337
1 Fit the assembly of the compound idler to its shaft, ensure that the "V" timing mark on the cra...2338
2 Fit the main idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Apply th...2338
3 Fit the adjustable idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Ap...2338
4 Fit the camshaft gear, if it was removed: align the hole in the gear with the dowel pin on the ...2338
5 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tigh...2338
6 Fit the gear case cover, Operation 6-1...2338
7 Remove the timing bolt from the flywheel and fit the cover and plug...2338
8 Install the rocker lever and shaft assemblies, Operation 3-2...2338
How to check the position of the timing gears Operation 6-3...2339
Gear case...2340
To remove and to fit Operation 6-4...2340
Consumable products...2340
Description...2340
Part number...2340
1 Remove the gear case cover, Operation 6-1...2340
2 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case...2340
3 Disconnect the lead and remove crankshaft timing sensor from behind the bottom of the gear case...2340
4 Remove the fan drive assembly, Operation 12-6...2340
5 Remove the coolant pump, Operation 12-13...2340
6 Remove the crankshaft vibration damper, Operation 5-4...2340
7 Remove the front engine support, Operation 7-1...2340
8 Remove the sump, Operation 10-3...2340
9 Remove the fuel transfer pump, Operation 11-2. If necessary, remove the drive for the fuel tran...2340
10 Remove the timing gears and the camshaft drive gear, Operation 6-2...2340
11 Remove the bolt and five nuts which retain the axle for the adjustable idler...2340
12 Remove the bolt and five nuts which retain the axle for the main idler...2340
13 Remove the three bolts which retain the camshaft front seal assembly. Remove the thrust plate,...2340
14 Attach a suitable hoist to the gear case and remove the mounting bolts...2340
15 Remove the gear case from the dowels in the crankcase. The weight of the gear case is approxim...2340
1 Clean thoroughly the contact surfaces of the crankcase and gear case...2341
2 Fit the two dowels, if they have been removed, and ensure that they protrude from the crankcase...2341
3 Ensure that the front surface of the crankcase is clean and fit a new joint to the crankcase...2341
4 Ensure that the rear face of the gear case is clean and fit the gear case onto the crankcase. F...2341
5 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaft...2341
6 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is wo...2341
7 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diamete...2341
8 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubrica...2341
9 Fit the timing gears, Operation 6-2...2341
10 Fit the sump, Operation 10-3...2341
11 Fit a new crankshaft front seal and wear sleeve, Operation 5-2...2341
12 Fit the front engine support, Operation 7-1...2341
13 Fit the crankshaft vibration damper, Operation 5-4...2341
14 Fit the coolant pump, Operation 12-13...2341
15 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the...2341
16 Fit the crankshaft timing sensor to its location behind the bottom of the gear case and connec...2341
17 Fit the gear case cover, Operation 6-1...2341
Crankcase and cylinder liners...2342
General information...2342
Front engine support...2343
To remove and to fit Operation 7-1...2343
1 Remove the radiator, Operation 12-4...2343
2 Use a suitable hoist, attached to the front lifting bracket, to support the engine and remove t...2343
3 Remove the eight bolts and washers (A1) and remove the engine support...2343
1 Fit the front engine support to the engine and retain with eight bolts and washers (A1)...2343
2 Attach the engine support to the base frame with the relevant bolts (A2), remove the hoist from...2343
3 Fit the radiator, Operation 12-4...2343
Cylinder liners...2344
To remove and to fit Operation 7-2...2344
Special tools...2344
Consumable products...2344
Description...2344
Part number...2344
Description...2344
Part number...2344
1 Remove the pistons and connecting rod assemblies, Operation 4-1...2344
2 Fit covers over the journals of the crankshaft for protection from dirt or water...2344
3 Use the special tool (A1), GE50001, to remove the cylinder liners (A2). Make a note of the bore...2344
1 Clean the cylinder liners and the liner bores in the crankcase...2344
2 Install the cylinder liners in the cylinder block without the ‘O’ ring seals or the filler band...2344
3 Check the protrusion of the cylinder liners, Operation 7-3...2344
4 Remove the liners and fit new ‘O’ ring seals...2344
5 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upp...2344
6 After the engine oil or liquid soap has been applied, immerse the filler band in clean engine o...2344
7 Fit the pistons and connecting rod assemblies, Operation 4-1...2344
To check and to adjust the protrusion of the cylinder liners Operation 7-3...2345
Special tools...2345
Description...2345
Part number...2345
Description...2345
Part number...2345
1 Ensure that the top face of the cylinder block (A4) is clean. Fit a new spacer plate gasket and...2345
2 Fit the cylinder liners to the cylinder block without seals or bands. Ensure that the cylinder ...2345
3 Install all of the bolts (A6), GE50005, or the six bolts around the liner (A5) to be checked. A...2345
4 Use the special tool, GE50002, to measure the liner protrusion at the four positions shown (B1,...2345
5 Add the four readings for each cylinder and divide the sum of the readings by four to obtain th...2345
6 If the liner protrusions are all below the specifications or low in the range, 0,025 mm (0.001 ...2346
7 When the liner protrusion is correct, add a temporary mark to the liner and to the spacer plate...2346
8 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upp...2346
Engine timing and electronic controls...2348
General information...2348
Electronic control module...2349
To remove and to fit Operation 8-1...2349
1 Switch off the engine and disconnect the electrical power supply...2349
2 Loosen fully the Allen screws from the J1 and J2 connectors (A1 and A4)...2349
3 Remove the two nuts which retain the bar (A6) and the control module (A3), release the ground s...2349
4 Support the control module, remove the two remaining nuts (A2 and A5) and remove the electronic...2349
1 Fit the electronic control module. Retain with four nuts, ensure that the ground strap is fitte...2349
2 Fit the connectors (A1 and A4) and retain with Allen screws. Tighten the screws to a torque of ...2349
3 Connect the electrical power supply...2349
Engine timing...2350
To check Operation 8-2...2350
Special tools...2350
Description...2350
Part number...2350
1 With the engine switched off and electrically isolated, remove the rocker cover, Operation 3-1...2350
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...2350
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2350
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2350
5 Attach a plunger clock and set the plunger on the top face of the rocker lever of the number on...2351
6 Rotate the engine in the normal direction of rotation until the timing bolt can again enter the...2351
7 Repeat step 6 to ensure that a consistent reading is obtained...2351
8 If the reading is not within the limits, adjust the position of the adjustable idler gear to ad...2351
Aspiration system...2352
General information...2352
Exhaust manifold...2353
To remove and to fit Operation 9-1...2353
Special tools...2353
Consumable products...2353
Description...2353
Part number...2353
Description...2353
Part number...2353
1 Remove the turbocharger, Operation 9-2...2353
2 Remove the thermostat housing, Operation 12-10...2353
3 Remove the exhaust shield...2353
4 Remove the nuts and spacers which retain the exhaust manifold and remove the manifold...2353
5 Withdraw the sleeves from the cylinder head...2353
6 Remove the gaskets from the cylinder head...2353
1 Check the condition of all sleeves, studs and nuts. Renew the components if worn or damaged. Ap...2353
2 Fit new gaskets over the studs and install the sleeves. Fit the exhaust manifold, fit the space...2353
3 Fit the thermostat housing, Operation 12-10...2353
4 Fit the turbocharger, Operation 9-2...2353
Turbocharger...2354
To remove and to fit Operation 9-2...2354
1 Disconnect the exhaust pipe from the turbocharger...2354
2 Remove the air duct from between the turbocharger and the air cleaner...2354
3 Disconnect the air duct from between the turbocharger and the charge air cooler...2354
4 Disconnect the oil feed (A2) and oil drain (A1) pipes...2354
5 Use a strap and hoist to support the turbocharger, remove the four bolts which retain the turbo...2354
1 Fit the turbocharger to the exhaust manifold. Apply CV60889 anti-seize compound to the bolts. F...2354
2 Connect the oil feed and oil drain pipes (A2 and A1)...2354
3 Fit the air duct between the turbocharger and the air cleaner...2354
4 Connect the air duct between the turbocharger and the charge air cooler...2354
5 Connect the exhaust pipe...2354
To dismantle and to assemble Operation 9-3...2355
1 Remove turbocharger, Operation 9-2...2355
2 Add temporary alignment marks between the bearing housing and both the compressor housing and t...2355
3 Loosen the nuts on the clamps and separate the compressor housing and the turbine housing from ...2355
4 Check the condition of all components. Renew any worn or damaged components...2355
1 Fit the compressor housing and the turbine housing to the bearing housing and retain with the r...2355
2 Adjust the position of both the compressor and turbine housings until the temporary marks are a...2355
3 Fit the turbocharger, Operation 9-2...2355
Lubrication system...2356
General information...2356
Oil filter and oil filter header...2357
To remove and to fit Operation 10-1...2357
1 Remove the plug (A5) and drain the oil from the oil filter housing...2357
2 Remove the oil filter housing (A3), and remove the oil filter element...2357
3 Remove the four bolts (A1) which connect the oil filter header to the oil cooler...2357
4 Remove the two bolts (A2) which retain the oil filter header on the crankcase...2357
5 Disconnect the turbocharger oil supply pipe from the elbow behind the oil cooler...2357
6 Remove the four bolts which retain the assembly of the elbow and oil filter header on the crank...2357
7 Remove the four bolts to separate the oil filter header from the elbow. Renew the ‘O’ ring seal...2357
1 Ensure that the ‘O’ ring seals are fitted to the elbow. Assemble the elbow and oil filter heade...2358
2 Ensure that the used gasket material has been removed from the mating faces. Fit the assembly t...2358
3 Fit the four bolts (A1) which retain the oil filter header to the oil cooler...2358
4 Connect the turbocharger oil supply pipe and tighten securely...2358
5 Clean the filter housing (A3) and clean the contact face of the filter head. Clean the drain pl...2358
6 Fit a new element into the filter housing, ensure that it engages fully with the guide in the b...2358
7 Fit the housing (A3) onto the filter head and tighten by use of a socket and torque wrench on t...2358
8 Check the amount of engine oil in the sump. If necessary, add more oil of the correct grade and...2358
9 Run the engine and check for leaks. Check again the amount of engine oil in the sump. If necess...2358
Oil filter header...2359
To dismantle and to assemble Operation 10-2...2359
1 Remove the two plugs (A5 and A6) which retain the by-pass valves in the oil filter header (A1)...2359
2 Remove the spring (A3) and the plunger (A2) for the oil cooler by-pass valve. Remove the spring...2359
3 Remove the two small plugs and the adaptor...2359
1 Fit the plunger (A9) and spring (A8) to the oil filter header...2359
2 Fit the plunger (A2) and spring (A3) to the oil filter header...2359
3 Fit the plugs (A5 and A6). Tighten each plug to 100 +/- 15 Nm (74 +/- 11 lbf ft)...2359
4 Fit the adaptor and the two small plugs. Tighten each of them to 25 +/- 5 Nm (18 +/- 4 lbf ft)...2359
Sump...2360
To remove and to fit Operation 10-3...2360
Consumable products...2360
Description...2360
Part number...2360
1 Drain the oil from the sump (A2)...2360
2 Loosen the bolts which retain the sump on the engine. Do not remove the bolts fully, allow them...2360
3 Remove the sump...2360
1 Examine the sump seal and renew if necessary. Ensure that the machined surface of the sump is c...2361
2 Clean the bottom face of the crankcase and also the bottom faces of the flywheel housing and th...2361
3 Apply a bead of RTV silicone sealant, CV60888, at the four positions where the edge of the flyw...2361
4 Fit the sump and tighten the bolts to a torque of 30 Nm (22 lbf ft); use the sequence shown (B)...2361
5 Fill the engine to the correct level with oil of the correct grade and specification. Refer to ...2361
Oil pump...2362
To remove and to fit Operation 10-4...2362
1 Remove the sump, Operation 10-3...2362
2 Remove the oil supply tube (A3) and the strainer and tube (A2)...2362
3 Remove the bolts and remove the oil pump (A4)...2362
1 Fit the oil pump to the crankcase...2362
2 Apply clean engine oil to the ‘O’ ring seals of the tubes...2362
3 Install oil supply tube (A3) and strainer and tube (A2)...2362
4 Fit the sump, Operation 10-3...2362
To dismantle and to assemble Operation 10-5...2363
1 Remove the bolt and washer which retain the gear on the shaft...2363
2 Use a suitable gear puller to remove drive gear (A1) from the shaft. Remove the key from the sh...2363
3 Remove retainer (A5) for the by-pass valve...2363
4 Remove the spring (A4) and the by-pass valve (A3)...2363
5 Remove the cover (A6) from the pump body (A2)...2363
6 Remove the idler gear and drive gear from pump body...2363
1 Apply clean engine oil to the idler gear and drive gear and install the gears in the oil pump b...2363
2 Fit the by-pass valve, the spring and the retainer to the pump body (A2)...2363
3 Fit the key to the shaft...2363
4 Fit the drive gear (A1) to the shaft. Install the washer and bolt which retain the gear. Tighte...2363
Fuel system...2364
General information...2364
Fuel priming pump...2365
To remove and to fit Operation 11-1...2365
1 Remove two bolts (A2) and remove fuel priming pump (A1)...2365
1 Inspect the gasket of the fuel priming pump; fit a new gasket if necessary...2365
2 Fit the fuel priming pump (A1) and retain with the two bolts (A2)...2365
Fuel transfer pump...2366
To remove and to fit Operation 11-2...2366
1 Disconnect the fuel pipes from the fuel transfer pump (A2)...2366
2 Use plugs or caps to seal temporarily all openings to prevent contamination of the fuel system...2366
3 Remove the bolts (A1) and withdraw the fuel transfer pump...2366
1 Check the condition of the ‘O’ ring seal on the fuel transfer pump, renew the seal if it is wor...2366
2 Ensure that the ‘O’ ring seal is fitted correctly to the fuel transfer pump. Apply a small amou...2366
3 Fit the fuel transfer pump (A2) and retain with two bolts (A1)...2366
4 Remove the plugs or caps from the fuel pipe openings and connect the fuel pipes...2366
5 Eliminate air from the fuel system, Operation 11-6...2366
To test Operation 11-3...2367
1 Run the pump at 2940 rev/min. The flow at 650 kPa (94 lb/in2) must be 4,5 litres/min (1.0 UK ga...2367
2 Run the pump at 840 rev/min. The flow at 550 kPa (80 lb/in2) must be 3,0 litres/min (0.66 UK ga...2367
3 Run the pump at 100 rev/min with the inlet to the atmosphere for 10 seconds. The pump must main...2367
Drive for the fuel transfer pump...2368
To remove and to fit Operation 11-4...2368
1 Remove the fuel transfer pump (A2), Operation 11-2...2368
2 Remove four bolts and washers (A1) and withdraw the assembly of the pump drive and housing (A3)...2368
3 Remove the three bolts from the housing (B1) and remove the assembly of the bearings and gear (...2368
4 Remove the ‘O’ ring seal (B3) from the housing...2368
5 Inspect all components, renew any which are worn or damaged...2368
1 Fit the assembly of the bearings and gear (B2) into the pump drive housing (B1)...2368
2 Retain the gear and bearings in the housing with the three bolts...2368
3 Fit a new ‘O’ ring seal (B3) to the housing...2368
4 Insert carefully the assembly of the pump drive and pump drive housing into the gear case. Reta...2368
5 Fit the fuel transfer pump, Operation 11-2...2368
Fuel filter header...2369
To remove and to fit Operation 11-5...2369
1 Remove the fuel priming pump (A2), Operation 11-1...2369
2 Disconnect the fuel pipes (A1, A3, A4 and A5). Fit plugs or caps to all openings to prevent con...2369
3 Remove the filter housings and elements from the fuel filter header...2369
4 Remove the bolts which retain the filter header on the crankcase...2369
1 Fit the filter header to the crankcase...2369
2 Remove any plugs or caps and connect the fuel pipes (A1, A3, A4 and A5)...2369
3 Renew the fuel filter elements in the primary and secondary fuel filter canisters. Use the proc...2369
4 Fit the fuel priming pump, Operation 11-1...2369
5 Eliminate air from the fuel system, Operation 11-6...2369
Low pressure fuel system...2370
How to eliminate air from the fuel system Operation 11-6...2370
1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) un...2370
2 Tighten the union (A1). Operate the hand priming pump until a strong pressure is felt on the pu...2370
3 Start the engine...2370
4 If the engine will not start, allow the starter motor to cool for 2 minutes. Repeat steps 1 and...2370
5 Run the engine with no load until it runs smoothly...2370
Cooling system...2372
General information...2372
Cooling system...2373
To inspect Operation 12-1...2373
1 Check the coolant level in the cooling system...2373
2 Check for leaks in the system...2373
3 Ensure that the air flow through the radiator is not restricted. Check for bent fins in the rad...2373
4 Inspect the drive belts for the fan...2373
5 Check for damage to the fan blades...2373
6 Check for air or combustion gas in the cooling system...2373
7 Inspect the filler cap and check the surface which the filler cap seals against. This surface m...2373
Leakage test Operation 12-2...2374
Special tools...2374
Description...2374
Part number...2374
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the ...2374
2 Ensure that the coolant is at the correct level...2374
3 Attach the pressurizing pump, GE50031, to the radiator and apply pressure until the reading on ...2374
4 Check the radiator for leakage...2374
5 Check all connection points and hoses for leakage...2374
Coolant filler cap...2375
To test Operation 12-3...2375
Special tools...2375
Description...2375
Part number...2375
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the ...2375
2 Carefully inspect the filler cap. Check for damage to the seals and to the sealing surface. Exa...2375
3 Check the opening pressure for the filler cap as follows: fit the filler cap to the pressurizin...2375
4 Apply pressure and check the gauge for the exact pressure which opens the filler cap...2375
5 Compare the reading on the gauge with the correct pressure which should open the filler cap, th...2375
6 Renew the filler cap if it is defective...2375
Radiator...2376
To remove and to fit Operation 12-4...2376
1 Drain the coolant into a suitable container...2376
2 Remove the air duct from between the charge air cooler and the air inlet elbow...2376
3 Remove the coolant pipe from between the thermostat housing and the top of the radiator...2376
4 Remove the fan guards...2376
5 Remove the air duct from between the turbocharger and the base of the charge air cooler...2376
6 Remove the coolant pipe from between the coolant pump elbow and the radiator...2376
7 Remove fasteners which retain the radiator to its base frame...2376
1 Fit the radiator to its base frame...2376
2 Fit the coolant pipe between the coolant pump elbow and the radiator...2376
3 Fit the air duct between the turbocharger and the base of the charge air cooler...2376
4 Fit the fan guards...2376
5 Fit the coolant pipe between the thermostat housing and the top of the radiator...2376
6 Fit the air duct between the charge air cooler and the air inlet elbow...2376
7 Fill the radiator with the correct coolant mixture. Refer to the User’s Handbook...2376
8 Run the engine until it reaches the normal temperature of operation and check for leaks...2376
Fan...2377
To remove and to fit Operation 12-5...2377
1 Switch off the engine and disconnect the electrical power supply...2377
2 Remove the fan guards...2377
3 Remove the bolts which retain the fan on the hub and remove the fan...2377
1 Fit the fan to the hub and retain with the six bolts...2377
2 Fit the fan guards...2377
3 Connect the electrical power supply...2377
Fan drive assembly...2378
To remove and to fit Operation 12-6...2378
1 Remove the fan, Operation 12-5...2378
2 Remove the hub (A1)...2378
3 Loosen the adjustment bolts to release the tension on the alternator belt. Remove the belt and ...2378
4 Release the tension on the fan drive belts and remove the belts...2378
5 Remove the two bolts and cap which retain the pulley (A2) and withdraw the pulley complete with...2378
6 Remove the two nuts and two bolts which retain the fan bearing housing (A4) and remove the hous...2378
1 Fit the fan bearing housing (A4)...2378
2 Fit the pulley (A2) and retain with the cap and two bolts. Tighten the bolts to a torque of 24 ...2378
3 Fit the fan drive belts and adjust the tension as given in Operation 12-7...2378
4 Fit the alternator (A3), fit the alternator belt and adjust the tension as given in Operation 1...2378
5 Fit the hub (A1)...2378
6 Fit the fan, Operation 12-5...2378
Fan drive belts...2379
To check and to adjust the tension Operation 12-7...2379
1 Remove the fan guards...2379
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A1). It should b...2379
3 Loosen the lock nuts on the adjustment bolt (A2), loosen the large lock nut on the belt tension...2379
4 Fit the fan guards and run the engine for 15 minutes. Remove the guards and check again the ten...2379
5 For new fan belts, set the tension to 868 N, which is equivalent to 4,0 mm of movement when a f...2379
6 When the correct tension is obtained, fit the fan guards...2379
To renew Operation 12-8...2380
1 Remove the fan, Operation 12-5...2380
2 Loosen the belt tensioner and remove the old belts. Ensure that the grooves of the pulley are f...2380
3 Fit the fan and tighten the bolts securely. Adjust the fan belts to the correct tension, as giv...2380
Engine oil cooler...2381
To remove and to fit Operation 12-9...2381
1 Drain the coolant from the engine...2381
2 Use a tray to collect any oil which may spill from the oil cooler during its removal...2381
3 Make temporary marks on the coolant duct (A2) and the oil cooler (A1) for correct alignment dur...2381
4 Remove the four bolts which retain the oil cooler (B1) on the oil filter header (B3)...2381
5 Withdrawn the oil cooler from the elbow (B2), take care not to damage the seal...2381
6 Remove the ‘O’ ring seal from the elbow (B2)...2381
1 Clean the core tubes of the oil cooler with a 3,81 mm (0.150 in) diameter rod...2381
2 Check the condition of the ‘O’ ring seals used on the oil cooler and the oil filter header. Ren...2381
3 Ensure that the ‘O’ ring seals are fitted to the oil filter header...2381
4 Fit the ‘O’ ring seal over the elbow (B2). Apply clean engine oil on the seal...2381
5 Align the oil cooler with the elbow and slide the oil cooler over the elbow. Fit the four bolts...2381
6 Fit an ‘O’ ring seal to the coolant duct (A2) and fit the duct to the oil cooler. Fit the four ...2381
7 Fill the cooling system with the correct coolant mixture. Refer to the User’s Handbook...2381
8 Check the amount of lubricating oil in the sump. Add lubricating oil of the correct grade, if n...2381
9 Clean away any oil or coolant which has been spilled...2381
Thermostats and thermostat housing...2382
To remove and to fit Operation 12-10...2382
1 Drain the coolant until the level is below the thermostat housing (A1)...2382
2 Disconnect the cable (A3) from the coolant temperature sensor...2382
3 Release the hose clips (A2) and disconnect the pipe and hose from the top of the unit...2382
4 If the thermostats are to be removed, loosen all five bolts of the thermostat housing; then rem...2382
5 Lift carefully the assembly to separate it from the coolant bobbin (A5) at its base...2382
1 Clean thoroughly both parts of the assembly and check the condition of the lip-type seals. Rene...2383
2 Fit the new thermostats. Ensure that the new thermostats are fitted correctly. Fit a new ‘O’ ri...2383
3 Ensure that the mating face on the cylinder head is clean. Fit new seals to the coolant bobbin ...2383
4 Connect the hose to the top of the housing and tighten the hose clip...2383
5 Connect the cable (A3) to the coolant temperature sensor...2383
6 Fill the coolant system to the correct level with the approved coolant mixture...2383
7 Operate the engine until it reaches the normal temperature of operation and check for leaks. St...2383
To test the thermostats Operation 12-11...2384
1 Remove the thermostats from the engine...2384
2 Heat water in a suitable container until the temperature is 98 C (208 F). Stir the water to e...2384
3 Suspend the thermostat in the container of water. The thermostat must be below the surface of t...2384
4 Ensure that the water is maintained at the correct temperature for ten minutes...2384
5 After ten minutes, remove the thermostat. Immediately check the distance that the thermostat ha...2384
Coolant temperature sensor...2385
To test Operation 12-12...2385
Special tools...2385
Description...2385
Part number...2385
1 When the engine is cool, release the coolant filler cap to relieve any pressure...2385
2 Remove one of the two plugs (A1) and install the special thermometer, GE50032. A temperature in...2385
3 Start the engine and run the engine until the temperature reaches the desired range according t...2385
Pointer...2385
position...2385
Test...2385
thermometer C...2385
Test...2385
thermometer F...2385
4 If the temperature sensor is renewed, do not attempt to disconnect the leads from the unit. Dis...2385
Coolant pump...2386
To remove and to fit Operation 12-13...2386
1 Drain the coolant from the engine into a suitable container for storage or disposal...2386
2 Remove the thermostat housing, Operation 12-10...2386
3 Remove the oil cooler, Operation 12-9...2386
4 Remove four bolts (A1) and the elbow (A2)...2386
5 Check the condition of the ‘O’ ring seal (B1), discard the seal if it is worn or damaged. Remov...2386
1 Fit the coolant pump to the gear case, ensure that the gear engages correctly. Tighten the bolts...2386
2 If necessary, fit a new ‘O’ ring seal (B1). Fit the elbow (A2) and retain with four bolts (A1)...2386
3 Fit the oil cooler, Operation 12-9...2386
4 Fit the thermostat housing, Operation 12-10...2386
5 Fill the coolant system to the correct level with the specified coolant mixture. Refer to the U...2386
To dismantle and to assemble Operation 12-14...2387
1 Remove the bolt (A15) and washer (A14). Use a suitable puller to remove the impeller (A11) from...2387
2 Remove the spring and seal (A13) from the shaft...2387
3 Remove the four bolts (A6) from the retainer (A7) and remove the ‘O’ ring seal (A9) from the ho...2387
4 Remove the gear and shaft assembly (A8). Remove the bolt (A4) and retainers (A3 and A7) from th...2387
5 Use a press to remove the shaft (A16) from the gear. Remove the bearing (A1), the spacer if fit...2387
6 Remove the lip-type seal (A12) from the housing...2387
1 Ensure that the shaft and the seal counter bore in the pump housing are clean...2388
2 Fit the bearing (A1), the spacer if relevant, and the second bearing (A2) to the shaft (A16)...2388
3 Fit the retainer (A7) and gear (A8) to the shaft assembly. Fit the second retainer (A3) and the...2388
4 Fit a new lip-type seal (A12) into the housing (A10). The seal must be fitted with the lip towa...2388
5 Fit a new ‘O’ ring seal (A9) to the housing...2388
6 Install the gear and shaft assembly in the housing. Fit the bolts (A6) which hold the retainer ...2388
7 Separate the spring from the seal assembly (A13). Use hand pressure to install the seal on the ...2388
8 Fit the impeller (A11) to the shaft and retain with the washer (A14) and bolt (A15). Tighten th...2388
9 Fit the coolant pump, Operation 12-13...2388
To test the pressure of the coolant pump Operation 12-15...2389
Special tools...2389
Description...2389
Part number...2389
1 To check that the coolant pump is operating correctly, the outlet pressure can be measured...2389
2 Remove the plug (A1) from the coolant manifold and connect the pressure gauge, GE50033, to the ...2389
3 Start the engine and run the engine until the normal temperature of operation is obtained...2389
4 Make a note of the reading on the pressure gauge. The pressure supplied by the coolant pump sho...2389
Flywheel and housing...2390
General information...2390
Flywheel...2391
To remove and to fit Operation 13-1...2391
1 Remove two of the flywheel bolts from horizontally opposite sides of the flywheel and insert tw...2391
2 Remove the bolts which remain and withdraw the flywheel from the crankshaft. Fit a suitable sli...2391
3 Remove the flywheel and remove the guide studs...2391
4 Remove the gear ring from the flywheel if necessary...2391
1 If the gear ring has been removed, heat the ring in an oven to a maximum temperature of 315 C ...2391
2 Fit suitable guide studs to bolt holes at horizontally opposite sides of the flywheel. Ensure t...2391
3 Attach a sling to the flywheel and use a hoist to locate the flywheel on the guide studs. Ensur...2391
4 Remove the sling and slide the flywheel up to the crankshaft...2391
5 Apply clean engine oil to the threads of the bolts which retain the flywheel and fit 10 of the ...2391
Flywheel housing...2392
To remove and to fit Operation 13-2...2392
Consumable products...2392
Description...2392
Part number...2392
1 Remove the flywheel, Operation 13-1...2392
2 Remove the crankshaft rear seal and wear sleeve, Operation 5-3...2392
3 Remove the starter motor, Operation 14-1...2392
4 Remove the sump, Operation 10-3...2392
5 Use a suitable hoist to support the flywheel housing and remove the bolts (A1 to A24) which ret...2392
6 Remove the flywheel housing from the dowels in the crankcase. The weight of the flywheel housin...2392
1 Clean thoroughly the contact surfaces of the crankcase and flywheel housing...2393
2 Fit the two dowels (B2 and B3) if they have been removed from the crankcase. They must protrude...2393
3 Apply a bead of liquid gasket, CH10879, to the area shown (B1)...2393
4 Attach a suitable hoist and fit the flywheel housing to the crankcase. Fit the bolts which reta...2393
5 Tighten the flywheel housing bolts as follows:...2393
6 Fit the sump, Operation 10-3...2393
7 Fit the starter motor, Operation 14-1...2393
8 Fit a new crankshaft rear seal and wear sleeve, Operation 5-3...2393
9 Fit the flywheel, Operation 13-1...2393
Electrical equipment...2394
General information...2394
Starter motor...2395
To remove and to fit Operation 14-1...2395
1 Disconnect the batteries before any service work is attempted...2395
2 Disconnect the wiring loom from the starter motor assembly (A2)...2395
3 Fasten a hoist to the starter motor. Remove the three bolts (A1) which retain the starter motor...2395
1 Use a hoist to support the starter motor. Fit the starter motor to the flywheel housing. Retain...2395
2 Connect the wiring loom to the starter motor. If the engine earth strap is connected to the sta...2395
3 Connect the batteries...2395
Alternator...2396
To remove and to fit Operation 14-2...2396
1 Disconnect the batteries before any service work is attempted...2396
2 Remove the access panel in the fan guard...2396
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley ...2396
4 Disconnect the wiring loom from the alternator...2396
5 Remove the bolts (A3 and A4) and remove the alternator...2396
1 Fit the alternator and retain with the pivot bolt (A3) and the adjustment link bolt (A4). Do no...2396
2 Fit the alternator drive belt over the alternator pulley and set the tension as given in Operat...2396
3 Connect the wiring loom to the alternator...2396
4 Fit the access panel to the fan guard...2396
5 Connect the batteries...2396
To check and to adjust the tension of the alternator belt Operation 14-3...2397
1 Remove the access panel in the fan guard and proceed as follows...2397
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A5). It should b...2397
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley ...2397
4 Fit the access panel to the fan guard and run the engine for 15 minutes. Remove the access pane...2397
5 If a new alternator belt is fitted, set the tension to 400 N, which is equivalent to 2,5 mm of ...2397
6 When the correct tension is obtained, fit the access panel to the fan guard...2397
To renew the alternator belt Operation 14-4...2398
1 Remove the fan, Operation 12-5...2398
2 Loosen the adjustment bolts to release the tension on the alternator belt and remove the old be...2398
3 Fit the fan, Operation 12-5...2398
4 Adjust the alternator belt to the correct tension, Operation 14-3...2398
Auxiliary equipment...2400
General information...2400
Oil sample valve...2400
Special tools...2402
List of special tools...2402
Tool number...2402
Description...2402
Illustration...2402
TSD3455E2 - Workshop Manual (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications))...2410
Perkins 2300 Series...2410
Models 2306A-E14 and 2306C-E14...2410
Workshop manual...2410
6 cylinder turbocharged diesel engines for industrial applications...2410
Chapters...2411
1 General information...2411
2 Specifications...2411
3 Cylinder head assembly...2411
4 Piston and connecting rod assemblies...2411
5 Crankshaft assembly...2411
6 Gear case and drive assembly...2411
7 Crankcase and cylinder liners...2411
8 Engine timing and electronic controls...2411
9 Aspiration system...2411
10 Lubrication system...2411
11 Fuel system...2411
12 Cooling system...2411
13 Flywheel and housing...2411
14 Electrical equipment...2411
15 Auxiliary equipment...2411
16 Special tools...2411
Publication TSD3455E, Issue 2...2410
© Proprietary information of Perkins Engines Company Limited, all rights reserved...2410
The information is correct at the time of print...2410
Published in December 2006 by Technical Publications,...2410
Perkins Engines Company Limited, Peterborough PE1 5NA England...2410
Contents...2412
1 General information...2412
Introduction 1...2412
Safety precautions 2...2412
Viton seals 4...2412
Welding 4...2412
Environmental protection 4...2412
Engine views 5...2412
Engine identification 6...2412
Engine lift equipment 6...2412
2 Specifications...2412
Basic engine data - 2306 engine 7...2412
Basic engine data - 2806 engine 7...2412
Rocker assemblies 8...2412
Valves 9...2412
Valve guides 10...2412
Valve springs 10...2412
Valve seat inserts 11...2412
Cylinder head 12...2413
Camshaft and bearings 12...2413
Pistons and connecting rods - 2306 engine 13...2413
Pistons and connecting rods - 2806 engine 14...2413
Crankshaft, main bearings and flywheel 15...2413
Crankshaft damper 15...2413
Crankcase and cylinder liners 16...2413
Lubricating oil pump 18...2413
Coolant pump 19...2413
Recommended torque figures 20...2413
3 Cylinder head assembly...2413
General information 27...2413
4 Pistons and connecting rod assemblies...2414
General information 57...2414
5 Crankshaft assembly...2414
General information 63...2414
6 Gear case and drive assembly...2414
General information 73...2414
7 Crankcase and cylinder liners...2415
General information 81...2415
8 Engine timing and electronic controls...2415
General information 87...2415
9 Aspiration system...2415
General information 91...2415
10 Lubrication system...2416
General information 95...2416
11 Fuel system...2416
General information 103...2416
12 Cooling system...2416
General information 111...2416
13 Flywheel and housing...2417
General information 129...2417
14 Electrical equipment...2418
General information 133...2418
15 Auxiliary equipment...2418
General information 139...2418
Oil sample valve 139...2418
16 Special tools...2418
List of special tools 141...2418
General information...2420
Introduction...2420
Safety precautions...2421
Viton seals...2423
Welding...2423
Environmental protection...2423
Engine views...2424
Engine identification...2425
Engine lift equipment...2425
Specifications...2426
Basic engine data - 2306 engine...2426
Basic engine data - 2806 engine...2426
Rocker assemblies...2427
Valves...2428
Valve guides...2429
Valve springs...2429
Valve seat inserts...2430
Cylinder head...2431
Camshaft and bearings...2431
Pistons and connecting rods - 2306 engine...2432
Pistons and connecting rods - 2806 engine...2433
Crankshaft, main bearings and flywheel...2434
Crankshaft damper...2434
Crankcase and cylinder liners...2435
Lubricating oil pump...2437
Coolant pump...2438
Recommended torque figures...2439
Standard torque figures for metric fasteners...2439
Metric nuts and bolts...2439
Thread size...2439
metric...2439
Standard torque...2439
Metric taperlock studs...2439
Thread size...2439
metric...2439
Standard torque...2439
Standard torque figures for imperial fasteners...2440
Imperial nuts and bolts...2440
Thread size...2440
inches...2440
Standard torque...2440
Imperial taperlock studs...2440
Thread size...2440
inches...2440
Standard torque...2440
Standard torque figures for ‘O’ ring face seal fittings and 37 degree flared fittings...2441
Torque figures for ferrous straight thread ‘O’ ring fittings when connected to ferrous materials...2441
Outside diameter of nominal tube...2441
Thread size...2441
Inches...2441
Standard...2441
torque...2441
‘O’ ring face seal fittings...2442
Torque figures for ferrous straight thread ‘O’ ring fittings (B)...2442
Thread size...2442
inches...2442
Standards torque...2442
Torque figures for flared and ‘O’ ring fittings...2443
Nuts for 37 degree flared fittings...2443
Outside diameter of nominal tube...2443
Thread size...2443
Inches...2443
Standard...2443
torque...2443
45 degree flared and 45 degree inverted flare fittings...2444
45 degree flared and 45 degree inverted flare fittings...2444
Outside diameter of nominal tube...2444
Thread size...2444
Inches...2444
Standard...2444
torque...2444
Tapered pipe thread fittings...2444
Tapered pipe thread fittings...2444
Thread size...2444
Inches...2444
Standard torque...2444
Threads with pipe sealant (CV60891)...2444
Threads without pipe sealant...2444
Torque figures for standard hose clamps of the worm drive band type...2445
Width of clamp...2445
Torque figure for initial...2445
installation on a new hose...2445
Torque figures for constant torque hose clamps...2445
Cylinder head assembly...2446
General information...2446
Rocker cover...2447
To remove and to fit Operation 3-1...2447
1 Disconnect the wiring harness at the socket on the rocker cover (A1)...2447
2 Disconnect and remove the engine breather pipe (A2)...2447
3 Loosen fully the bolts which retain the rocker cover, but do not remove the bolts from the asse...2447
4 Remove the rocker cover...2447
1 Inspect the seal of the rocker cover and renew if worn of damaged...2447
2 Fit the rocker cover, complete with seal and bolts. Tighten the bolts to a torque of 20 Nm (15 ...2447
3 Fit the engine breather pipe (A2)...2447
4 Connect the wiring harness. Ensure that the wiring harness is fully engaged with the connector...2447
Rocker lever and rocker shaft assemblies...2448
To remove and to fit Operation 3-2...2448
1 Remove the rocker cover, Operation 3-1...2448
2 The valve rocker levers (A1) and the unit injector rocker levers (A2) can move on the shaft (A6...2448
3 Remove the four bolts (A5)...2448
4 Remove the shaft (A6), valve rocker levers (A1) and unit injector rocker levers (A2) as a unit...2448
5 Repeat steps 1 and 2 for the rocker shaft assemblies which remain...2448
1 Loosen the adjustment screws (A3 and A4) of each of the rocker levers which have been removed. ...2448
2 Set the tappet clearances, Operation 3-4...2448
3 Check/adjust the unit injectors, Operation 3-13...2448
4 Fit the rocker cover, Operation 3-1...2448
To dismantle and to assemble Operation 3-3...2449
1 Slide the valve rocker levers (A3) and the unit injector rocker levers (A4) from the shaft (A7)...2449
2 Remove the button (A1) from the adjustment screw (A2) in the valve rocker lever (A3)...2449
3 Remove the button (A6) from the adjustment screw (A5) in the unit injector rocker lever (A4)...2449
4 Repeat steps 1 to 3 for the rocker lever assemblies which remain...2449
1 Install new ‘O’ ring seals in the buttons (A1)...2450
2 Install new ‘O’ ring seals in the buttons (A6)...2450
3 To fit the ‘O’ ring seals and buttons to the valve rocker levers, proceed as follows:...2450
4 To fit the ‘O’ ring seals and buttons to the unit injector rocker levers, proceed as follows:...2450
5 Repeat steps 3 and 4 for the rocker levers which remain...2450
6 Fit the assembled rocker levers to the shafts (A7). Ensure that they are fitted to their origin...2450
How to check/adjust the tappet clearances Operation 3-4...2451
Special tools...2451
Tappet clearances...2451
Description...2451
Part number...2451
Inlet...2451
Exhaust...2451
1 Remove the rocker cover, Operation 3-1...2451
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...2451
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2451
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2451
5 Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the pisto...2452
6 Before each set of tappet clearances is adjusted, ensure that the roller of the rocker lever is...2452
7 Use a set of feeler gauges, inserted at the position shown (B3) between the valve bridge piece ...2452
8 After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a ...2453
9 Withdraw the timing bolt and rotate the flywheel by 360 degrees so that the number 6 piston is ...2453
10 Check the tappet clearances for the inlet valves (C1) on cylinders 3, 5 and 6. Adjust the clea...2453
11 After each unit has been adjusted, tighten the lock nut of the adjustment screw to a torque of...2453
12 Check again the tappet clearances for all six cylinders...2453
13 Fit the rocker cover. Remove the engine turning tool and the timing bolt and fit the cover to ...2453
Cylinder head assembly...2454
To remove and to fit Operation 3-5...2454
Special tools...2454
Consumable products...2454
Description...2454
Part number...2454
Description...2454
Part number...2454
1 Remove the thermostat housing, Operation 12-10...2454
2 Remove the exhaust manifold, Operation 9-1...2454
3 Remove the rocker lever and rocker shaft assemblies, Operation 3-2...2454
4 Remove the electronic unit injectors, Operation 3-12...2454
5 Remove the gear case cover, Operation 6-1...2454
6 Disconnect the cable and remove the timing sensor from the cylinder head...2454
7 Remove the support bracket which is fitted between the gear case and the cylinder head...2454
8 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bol...2454
9 Disconnect the fuel lines from the front and rear of the cylinder head. Fit temporary covers to...2454
10 Remove the cylinder head bolts; use the special socket, GE50020...2454
11 Fit the lifting bracket (A1), VP12712, to the cylinder head and attach a suitable hoist. Remov...2454
12 Remove the cylinder head gasket (B4)...2455
13 Remove the ‘O’ ring seal from the oil transfer tube (B6) and remove the 24 coolant seals (B3)...2455
14 Remove the seal (B2)...2455
15 Remove the spacer plate (B5) and discard the spacer plate gasket...2455
16 Remove the second ‘O’ ring seal from the oil transfer tube (B6)...2455
1 If the oil transfer tube (B6) has been removed, apply retaining compound, 21820 638, and insert...2456
2 If the rear dowel has been removed, apply retaining compound, 21820 638, and insert it in the c...2456
3 If the front dowel, close to the oil transfer tube, has been removed, it must be fitted in a dr...2456
4 Fit suitable guide studs (B1) to the cylinder block. Fit a new spacer plate gasket over the dow...2456
5 Fit a new ‘O’ ring seal to the oil transfer tube (B6)...2456
6 Fit the spacer plate (B5) and fit the second ‘O’ ring seal to the oil transfer tube (B6). Fit t...2456
7 Check, and if necessary adjust, the protrusion of the cylinder liners, Operation 7-3...2456
8 Fit a new cylinder head gasket (B4) to the spacer plate...2456
9 Fasten a hoist to the cylinder head, use the lifting bracket VP12712, and lower the cylinder he...2457
10 Apply special lubricant, CV60895, to the washers, the threads and under the heads of the bolts...2457
11 Fit the camshaft gear. Check and, if necessary, adjust the backlash between the camshaft gear ...2457
12 Fit the gear case cover, Operation 6-1...2457
13 Fit the support bracket between the cylinder head and the gear case...2457
14 Fit the electronic unit injectors, Operation 3-12...2457
15 Fit the rocker lever and shaft assemblies, Operation 3-2...2457
16 Fit the exhaust manifold, Operation 9-1...2457
17 Fit the thermostat housing, Operation 12-10...2457
18 Remove the covers from the fuel lines and from the fuel line ports on the cylinder head. Conne...2457
19 Fit the timing sensor and connect the cable...2457
Valve springs...2458
To remove and to fit Operation 3-6...2458
Special tools...2458
Description...2458
Part number...2458
1 Remove the rocker lever and rocker shaft assemblies, Operation 3-2...2458
2 Remove the electronic unit injectors, Operation 3-12...2458
3 Set the piston for the relevant valve spring assembly to the top of its compression stroke...2458
4 Use the hold-down clamp from the electronic unit injector to secure the valve spring compressor...2458
5 Insert the stud and base of the valve spring compressor into the bore of the injector sleeve. U...2458
6 Tighten the nut until the collets are loose on the valves...2458
7 Remove two collets from each valve...2458
8 Loosen slowly, then remove the nut, washer, thrust bearing and plate...2458
9 Remove the rotocoils, valve springs and washers from each valve...2458
10 Inspect the valve springs, refer to Chapter 2, Specifications for the correct dimensions and s...2458
11 Repeat steps 3 to 10 for the other valve spring assemblies which are to be removed...2458
1 Apply clean engine oil to the relevant valve stems...2459
2 Fit the washer, valve spring and rotocoil to each valve...2459
3 Use the valve spring compressor, GE50026, to compress the valve springs...2459
4 Fit two collets to each valve...2459
5 Loosen slowly and then remove the nut (A2) and plate (A1) of the valve spring compressor. Remov...2459
6 Tap lightly each valve with a soft hammer to ensure that the collets are seated correctly...2459
7 Fit the electronic unit injectors, Operation 3-12...2459
8 Fit the rocker lever and rocker shaft assemblies, Operation 3-2...2459
Valves...2460
To remove and to fit Operation 3-7...2460
Special tools...2460
Description...2460
Part number...2460
1 Remove the cylinder head, Operation 3-5...2460
2 Put the cylinder head, flame face down, on a bench with a soft surface and release the valves b...2460
3 Withdraw the valves from the cylinder head...2460
4 Repeat the procedure for all valves which are to be removed...2460
1 Apply clean engine oil to the stems of the valves. Fit the valves to their original positions i...2460
2 Use the special tool, GE50026, and the procedure given in Operation 3-6, to install the valve s...2460
3 Fit the cylinder head, Operation 3-5...2460
Valve seals...2461
To renew Operation 3-8...2461
Special tools...2461
Description...2461
Part number...2461
1 Remove the relevant valve spring assembly, Operation 3-6...2461
2 Remove the valve seal from the valve and valve guide...2461
3 Apply a thin film of clean engine oil to the new valve seal and slide the seal over the valve s...2461
4 If the valve seal is to be fitted to a valve guide with the valve removed, fit the seal to the ...2461
5 Use the special tool, GE50027, and hand pressure only to push the valve seal into its position ...2461
6 Withdraw the tool and fit the valve spring assembly, Operation 3-6...2461
Valve guides...2462
To remove and to fit Operation 3-9...2462
Special tools...2462
Description...2462
Part number...2462
1 Remove the cylinder head, Operation 3-5...2462
2 Remove the valves, Operation 3-7...2462
3 Use the special tool (A1), GE50043, and a hammer to drive the valve guide (A2) from the cylinde...2462
1 Apply clean engine oil to the outside diameter of the new valve guides...2463
2 Use the special tool (B1), GE50043, together with the sleeve (B2), GE50044, to install the valv...2463
3 When a new valve guide has been fitted, check that there is full contact between the valve and ...2463
4 Fit the valves, Operation 3-7...2463
5 Fit the cylinder head, Operation 3-5...2463
Camshaft...2464
To remove and to fit Operation 3-10...2464
Special tools...2464
Consumable products...2464
Description...2464
Part number...2464
Description...2464
Part number...2464
1 Remove the radiator, Operation 12-4...2464
2 Remove the fan, Operation 12-5...2464
3 Remove the gear case cover, Operation 6-1...2464
4 Remove the rocker cover, Operation 3-1...2464
5 Remove the rocker lever and shaft assemblies, Operation 3-2...2464
6 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...2464
7 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2464
8 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2465
9 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case...2465
10 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bo...2465
11 Attach a hoist to the camshaft gear and withdraw the gear from the camshaft. Remove the guide ...2465
12 Remove three bolts and withdraw the thrust plate, the adaptor plate and the seal assembly...2465
13 Use the bolts of the rocker shaft to retain the cradle tool (B1), GE50018, at the position sho...2465
14 Remove the rear cover (C1), complete with seal (C3)...2466
15 Fit the camshaft guide (D1), GE50017, to the gear case. Do not tighten the bolts for the guide...2466
16 Install a pilot tool, GE50015, into the threaded hole at the rear end of the camshaft. Then at...2466
17 Withdraw the camshaft until it enters the bore of the camshaft guide. Tighten the bolts which ...2466
18 Use the lifting hooks, GE50025, to move the camshaft toward the front of the engine...2466
19 Withdraw the camshaft from the cylinder head just enough for a strap and hoist to be attached...2466
1 Fit the two pilot tools, GE50015, to the rear end of the camshaft. Ensure that the camshaft and...2467
2 Fit the camshaft guide (E1), GE50017, to the gear case cover, but do not tighten the bolts fully...2467
3 Insert the alignment sleeve (E2), GE50016, through the camshaft guide (E1) and into the camshaf...2467
4 Fit the cradle tool (F1), GE50018, at the position shown (F)...2467
5 Use a suitable strap and hoist to support the camshaft. Insert the camshaft through the guide a...2467
6 Remove the strap and hoist. Rotate the camshaft during installation. Do not allow the end of th...2467
7 Remove the pilot tools and push the camshaft fully into its bore...2467
8 Inspect the seal (G3) and renew if necessary. Fit the rear cover (G1), complete with seal (G3)...2467
9 Remove the cradle tool and the camshaft guide...2468
10 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubric...2468
11 Fit the guide stud, GE50019, to the camshaft...2468
12 Fit the camshaft gear; align the hole in the gear with the dowel pin on the adapter plate. If ...2468
13 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tig...2468
14 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the...2468
15 Fit the gear case cover, Operation 6-1...2468
16 Remove the timing bolt from the flywheel and fit the cover and plug...2468
17 Install the rocker lever and shaft assemblies, Operation 3-2...2468
How to set the backlash for the camshaft gear Operation 3-11...2469
1 Remove the main idler gear (A3). Hold the camshaft gear stationary and use a dial test indicato...2469
2 Fit the main idler gear (A3), hold the main idler gear stationary and measure the backlash on t...2469
3 To adjust the backlash, remove the three bolts and thrust plate which retain the adjustable idl...2469
4 Fit the idler gear. Retain with the thrust plate and three bolts. Check again the backlash betw...2469
5 When the correct backlash settings have been obtained, remove the adjustable idler gear and pro...2469
Electronic injector units...2470
To remove and to fit Operation 3-12...2470
Special tools...2470
Description...2470
Part number...2470
Description...2470
Part number...2470
1 Remove the relevant rocker shaft assembly, Operation 3-2...2470
2 Loosen the two nuts and remove the electrical connector from the injector unit...2470
3 Mark the valve bridge pieces to assist during assembly, then remove them...2470
4 Remove the bolt (A2) from the spacer and clamp which retain the injector unit and use the speci...2470
5 Remove the injector unit, together with the spacer and clamp...2470
6 Use the vacuum pump, GE50028, together with the tube, GE50030, and bottle, GE50029, to extract ...2470
1 Clean thoroughly the bore of the injector sleeve and cylinder head. Use the special brushes (GE...2471
2 Check the condition of the ‘O’ ring seals (B1 and B2); renew the seals if they are worn or dama...2471
3 Fit the injector unit to the cylinder head. Fit the clamp, spacer and retaining bolt. Tighten t...2471
4 Fit the bridge pieces...2471
5 Attach the electrical connector to the injector unit and retain with the two nuts. Tighten the ...2471
6 Fit the rocker shaft assembly, Operation 3-2...2471
To check and to adjust Operation 3-13...2472
Special tools...2472
Description...2472
Part number...2472
1 With the rocker covers removed, set the number 1 piston to TDC (top dead centre) on its compres...2472
2 Use the fuel injector setting gauge, CH11149, to obtain the correct height for the fuel injecto...2472
3 Remove the timing bolt from the flywheel housing and rotate the flywheel by 360 degrees in the ...2472
4 Check/adjust the height dimensions for the fuel injectors of cylinders 1, 2 and 4 as given in s...2472
Injector sleeves...2473
To remove and to fit Operation 3-14...2473
Special tools...2473
Description...2473
Part number...2473
Description...2473
Part number...2473
1 Remove the rocker shaft assemblies, Operation 3-2...2473
2 Remove the electronic injector units, Operation 3-12...2473
3 Mark the bridge pieces and make a note of their position to assist during assembly, then remove...2473
4 Fit the puller stud from the special tool, GE50021, into the injector sleeve as shown (A). Fit ...2473
5 Remove the ‘O’ ring seals from the injector sleeve. Check the condition of the injector sleeve ...2473
6 Repeat steps 1 to 5 for the injector sleeves which remain...2473
1 Use the brushes, special tool numbers: GE50023, GE50024 and GE50022, to clean thoroughly the bo...2474
2 Fit new ‘O’ ring seals to the injector sleeve...2474
3 Fit the stud from the special tool into the threads of the injector sleeve...2474
4 Apply CV60889 anti-seize compound to the ‘O’ ring seals and to the large diameter (B1) off the ...2474
5 Apply CV60893 retaining compound to the small diameter (B2) off the injector sleeve...2474
6 Using the stud, insert the injector sleeve into its bore in the cylinder head. Take care to pre...2474
7 Fit the driver tool over the stud and tap lightly with a hammer to ensure that the injector sle...2474
8 Use a clean cloth to remove any retaining or anti-seize compound from the bores of the cylinder...2474
9 Fit the electronic injector units, Operation 3-12...2474
10 Fit the rocker shaft assemblies, Operation 3-2...2474
Pistons and connecting rod assemblies...2476
General information...2476
Pistons and connecting rod assemblies...2477
To remove and to fit Operation 4-1...2477
Special tools...2477
Consumable products...2477
Description...2477
Part number...2477
Description...2477
Part number...2477
1 Remove the cylinder head assembly, Operation 3-5...2477
2 Remove the oil pump, Operation 10-4...2477
3 Remove the stiffener plate from the base of the crankcase...2477
4 Remove the carbon ridge from the top inside surface of the cylinder liners...2477
5 Turn the crankshaft until two pistons are at bottom centre...2477
6 Remove the bolts (A1) and the bearing caps. Push the connecting rods and pistons up until the r...2477
7 Withdraw carefully the pistons and connecting rods from the cylinder liners. Store the bearing ...2477
8 Repeat steps 3 to 6 for the remainder of the pistons and connecting rods...2477
1 Apply clean engine oil to the piston rings, the connecting rod bearings and the cylinder liners...2478
2 Ensure that the piston ring gaps are set at 120 degree intervals to each other...2478
3 Use the special tool (B1), GE50003 for 2806 engines or GE50045 for 2306 engines, to install the...2478
4 Fit the bearing cap to the connecting rod. The cap must be fitted with its number on the same s...2478
5 Apply anti-seize compound, CV60890, to the bolt threads. Install the bolts and bearing cap. Tig...2478
6 Repeat steps 1 to 4 for the remainder of the pistons and connecting rods...2478
7 Fit the stiffener plate to the base of the crankcase...2478
8 Fit the oil pump, Operation 10-4...2478
9 Fit the cylinder head assembly, Operation 3-5...2478
To dismantle and assemble Operation 4-2...2479
1 Remove the pistons and connecting rod assemblies, Operation 4-1...2479
2 Remove the big-end bearing shells (A5) from the connecting rod (A4) and connecting rod cap. If ...2479
3 Remove the circlips (A1)...2479
4 Remove the gudgeon pin (A2) and separate the connecting rod and the piston crown from the piston...2479
5 Remove carefully the piston rings (A3) from the piston crown and clean the piston ring grooves ...2479
1 Check the gaps between the ends of the piston rings when the rings are inserted in a new liner...2480
2 Fit the spring of the oil control ring to its groove in the piston crown...2480
3 Use a suitable piston ring expander to fit the oil control ring to its groove in the piston crown...2480
4 Fit the second (intermediate) piston ring with the side that has the identification "UP-2" towa...2480
5 Fit the first (top) piston ring with the side that has the identification "UP-1" toward the top...2480
6 When all three piston rings have been fitted, adjust the position of the piston ring gaps so th...2480
7 Fit the piston crown into the piston skirt and insert the connecting rod. Apply clean engine oi...2480
8 Fit the big-end bearings to the connecting rod (A4) and connecting rod cap. If the original bea...2480
9 Fit the pistons and connecting rod assemblies, Operation 4-1...2480
Piston cooling jets...2481
To remove and to fit Operation 4-3...2481
Special tools...2481
Description...2481
Part number...2481
1 Remove oil pump, Operation 10-4...2481
2 Use the engine turning tool, CH11148, to turn the crankshaft in a clockwise direction (as seen ...2481
3 Remove the bolt which retains the cooling jet and remove the cooling jet from the engine...2481
4 Repeat steps 2 and 3 for the cooling jets which remain...2481
1 Before a piston cooling jet is fitted to the engine, use the jet alignment tool, GE50004, to en...2481
2 Carefully fit the piston cooling jets to the engine, ensure that the nozzles of the cooling jet...2481
3 Fit the oil pump, Operation 10-4...2481
Crankshaft assembly...2482
General information...2482
Crankshaft...2483
To remove and to fit Operation 5-1...2483
Consumable products...2483
Description...2483
Part number...2483
1 Remove the gear case cover, Operation 6-1...2483
2 Remove the flywheel housing, Operation 13-2...2483
3 Remove the pistons and connecting rod assemblies, Operation 4-1...2483
4 Remove the crankshaft rear seal and wear sleeve, Operation 5-3...2483
5 Remove the crankshaft front seal and wear sleeve, Operation 5-2...2483
6 Remove the bolts (A1) which retain the main bearing caps in the crankcase and remove the bearin...2483
7 Fit one of the bolts from the front pulley to each end of the crankshaft. Fasten a hoist to the...2483
1 Clean the crankcase and the main bearing caps thoroughly. Apply clean engine oil to the main be...2484
2 Install one of the bolts from the front pulley in each end of the crankshaft, fasten a suitable...2484
3 Fit the thrust bearings for the centre main bearing. Ensure that the bearings are fitted with t...2484
4 Fit the main bearings to the bearing caps...2484
5 Ensure that the tabs on the back of the bearing shells fit into the tab slots of the bearing ca...2484
6 Apply anti-seize compound, CV60890, to the bolts and install the main bearing caps and bolts...2484
7 Begin at the tab end of the bearing cap first, tighten each bearing cap bolt to a torque of 260...2484
8 Use a dial test indicator (DTI) to check the end-float of the crankshaft. Ensure that the point...2484
9 Fit the crankshaft front seal and wear sleeve, Operation 5-2...2484
10 Fit the crankshaft rear seal and wear sleeve, Operation 5-3...2484
11 Fit the pistons and connecting rod assemblies, Operation 4-1...2484
12 Fit the flywheel housing, Operation 13-2...2484
13 Fit the gear case cover, Operation 6-1...2484
Crankshaft front seal and wear sleeve...2485
To renew Operation 5-2...2485
Special tools...2485
Consumable products...2485
Description...2485
Part number...2485
Description...2485
Part number...2485
1 Remove the vibration damper, Operation 5-4...2485
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapp...2485
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the ...2485
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With ...2485
5 Remove the distorter tool, the protection ring and the wear sleeve...2485
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure prime...2486
2 Use the bolts (C3), GE50009, to install the guide, GE50008, on the crankshaft...2486
3 Fit the wear sleeve and seal (C4) as a unit onto the locator, GE50008...2486
4 Fit the installer (C2), GE50012, onto the locator...2486
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the ins...2486
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in ...2486
7 Remove all of the tools from the crankshaft...2486
8 Fit the vibration damper, Operation 5-4...2486
Crankshaft rear seal and wear sleeve...2487
To renew Operation 5-3...2487
Special tools...2487
Consumable products...2487
Description...2487
Part number...2487
Description...2487
Part number...2487
1 Remove the flywheel, Operation 13-1...2487
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapp...2487
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the ...2487
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With ...2487
5 Remove the distorter tool, the protection ring and the wear sleeve...2487
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure prime...2488
2 Use the bolts (C4), GE50009, to install the guide, GE50008, on the crankshaft...2488
3 Fit the wear sleeve and seal (C3) as a unit onto the locator, GE50008...2488
4 Fit the installer (C2), GE50012, onto the locator...2488
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the ins...2488
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in ...2488
7 Remove all of the tools from the crankshaft...2488
8 Fit the flywheel, Operation 13-1...2488
Crankshaft vibration damper...2489
To remove and to fit Operation 5-4...2489
1 Remove the fan guards...2489
2 Slacken the tension on the fan drive belts, then remove the belts from the crankshaft pulley (A1)...2489
3 Attach a strap and a suitable lifting device to the vibration damper (A2). Remove the six bolts...2489
4 Remove damper and adapter. The weight of the vibration damper is approximately 25 kg (55 lb)...2489
1 Attach a strap and a suitable lifting device to the vibration damper (A2). Use a 5/8 -18 x 6 in...2490
2 Fit the crankshaft pulley (A1). Apply clean engine oil to the threads of the bolts and install ...2490
3 Remove the guide stud and install the final bolt and washer. Tighten the bolts to a torque of 2...2490
4 Fit the fan belts and adjust the tension as given in Operation 12-7...2490
5 Fit the fan guards...2490
Gear case and drive assembly...2492
General information...2492
Gear case cover...2493
To remove and to fit Operation 6-1...2493
1 Remove the radiator, Operation 12-4...2493
2 Remove the fan, Operation 12-5...2493
3 Loosen the bolts which retain the gear case cover. Do not remove the bolts from the assembly, a...2493
4 Remove the gear case cover...2493
1 Examine the seal and renew if necessary, clean the contact surfaces of the seal and the gear case...2493
2 Fit the gear case cover and tighten the bolts, in the sequence shown (A), to a torque of 20 Nm ...2493
3 Fit the fan, Operation 12-5...2493
4 Fit the radiator, Operation 12-4...2493
Timing gears...2494
To remove and to fit Operation 6-2...2494
Special tools...2494
Consumable products...2494
Description...2494
Part number...2494
Description...2494
Part number...2494
1 Remove the gear case cover, Operation 6-1, and set the engine to the correct timing position fo...2494
2 Remove the top bolt (A1) from the cover (A2) on the flywheel housing and loosen the other cover...2494
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2494
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2494
5 Remove the rocker lever and rocker shaft assemblies, Operation 3-2. If the camshaft gear (C2) i...2495
6 Remove the camshaft gear (C2), if relevant. Use the guide stud, GE50019. If the gear case is to...2495
7 Remove the three bolts and the thrust plate (C3) and remove the adjustable idler. Discard the b...2495
8 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...2495
9 Remove the three bolts and the thrust plate (C4) and remove the main idler. Discard the bolts...2495
10 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...2495
11 Remove the four bolts and the thrust plate (C1) and withdraw the compound idler. Discard the b...2495
12 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged...2495
13 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaf...2495
14 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is w...2495
15 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diamet...2495
1 Fit the assembly of the compound idler to its shaft, ensure that the "V" timing mark on the cra...2496
2 Fit the main idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Apply th...2496
3 Fit the adjustable idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Ap...2496
4 Fit the camshaft gear, if it was removed: align the hole in the gear with the dowel pin on the ...2496
5 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tigh...2496
6 Fit the gear case cover, Operation 6-1...2496
7 Remove the timing bolt from the flywheel and fit the cover and plug...2496
8 Install the rocker lever and shaft assemblies, Operation 3-2...2496
How to check the position of the timing gears Operation 6-3...2497
Gear case...2498
To remove and to fit Operation 6-4...2498
Consumable products...2498
Description...2498
Part number...2498
1 Remove the gear case cover, Operation 6-1...2498
2 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case...2498
3 Disconnect the lead and remove crankshaft timing sensor from behind the bottom of the gear case...2498
4 Remove the fan drive assembly, Operation 12-6...2498
5 Remove the coolant pump, Operation 12-13...2498
6 Remove the crankshaft vibration damper, Operation 5-4...2498
7 Remove the front engine support, Operation 7-1...2498
8 Remove the sump, Operation 10-3...2498
9 Remove the fuel transfer pump, Operation 11-2. If necessary, remove the drive for the fuel tran...2498
10 Remove the timing gears and the camshaft drive gear, Operation 6-2...2498
11 Remove the bolt and five nuts which retain the axle for the adjustable idler...2498
12 Remove the bolt and five nuts which retain the axle for the main idler...2498
13 Remove the three bolts which retain the camshaft front seal assembly. Remove the thrust plate,...2498
14 Attach a suitable hoist to the gear case and remove the mounting bolts...2498
15 Remove the gear case from the dowels in the crankcase. The weight of the gear case is approxim...2498
1 Clean thoroughly the contact surfaces of the crankcase and gear case...2499
2 Fit the two dowels, if they have been removed, and ensure that they protrude from the crankcase...2499
3 Ensure that the front surface of the crankcase is clean and fit a new joint to the crankcase...2499
4 Ensure that the rear face of the gear case is clean and fit the gear case onto the crankcase. F...2499
5 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaft...2499
6 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is wo...2499
7 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diamete...2499
8 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubrica...2499
9 Fit the timing gears, Operation 6-2...2499
10 Fit the sump, Operation 10-3...2499
11 Fit a new crankshaft front seal and wear sleeve, Operation 5-2...2499
12 Fit the front engine support, Operation 7-1...2499
13 Fit the crankshaft vibration damper, Operation 5-4...2499
14 Fit the coolant pump, Operation 12-13...2499
15 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the...2499
16 Fit the crankshaft timing sensor to its location behind the bottom of the gear case and connec...2499
17 Fit the gear case cover, Operation 6-1...2499
Crankcase and cylinder liners...2500
General information...2500
Front engine support...2501
To remove and to fit Operation 7-1...2501
1 Remove the radiator, Operation 12-4...2501
2 Use a suitable hoist, attached to the front lifting bracket, to support the engine and remove t...2501
3 Remove the eight bolts and washers (A1) and remove the engine support...2501
1 Fit the front engine support to the engine and retain with eight bolts and washers (A1)...2501
2 Attach the engine support to the base frame with the relevant bolts (A2), remove the hoist from...2501
3 Fit the radiator, Operation 12-4...2501
Cylinder liners...2502
To remove and to fit Operation 7-2...2502
Special tools...2502
Consumable products...2502
Description...2502
Part number...2502
Description...2502
Part number...2502
1 Remove the pistons and connecting rod assemblies, Operation 4-1...2502
2 Fit covers over the journals of the crankshaft for protection from dirt or water...2502
3 Use the special tool (A1), GE50001, to remove the cylinder liners (A2). Make a note of the bore...2502
1 Clean the cylinder liners and the liner bores in the crankcase...2502
2 Install the cylinder liners in the cylinder block without the ‘O’ ring seals or the filler band...2502
3 Check the protrusion of the cylinder liners, Operation 7-3...2502
4 Remove the liners and fit new ‘O’ ring seals...2502
5 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upp...2502
6 After the engine oil or liquid soap has been applied, immerse the filler band in clean engine o...2502
7 Fit the pistons and connecting rod assemblies, Operation 4-1...2502
To check and to adjust the protrusion of the cylinder liners Operation 7-3...2503
Special tools...2503
Description...2503
Part number...2503
Description...2503
Part number...2503
1 Ensure that the top face of the cylinder block (A4) is clean. Fit a new spacer plate gasket and...2503
2 Fit the cylinder liners to the cylinder block without seals or bands. Ensure that the cylinder ...2503
3 Install all of the bolts (A6), GE50005, or the six bolts around the liner (A5) to be checked. A...2503
4 Use the special tool, GE50002, to measure the liner protrusion at the four positions shown (B1,...2503
5 Add the four readings for each cylinder and divide the sum of the readings by four to obtain th...2503
6 If the liner protrusions are all below the specifications or low in the range, 0,025 mm (0.001 ...2504
7 When the liner protrusion is correct, add a temporary mark to the liner and to the spacer plate...2504
8 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upp...2504
Engine timing and electronic controls...2506
General information...2506
Electronic control module...2507
To remove and to fit Operation 8-1...2507
1 Switch off the engine and disconnect the electrical power supply...2507
2 Loosen fully the Allen screws from the J1 and J2 connectors (A1 and A4)...2507
3 Remove the two nuts which retain the bar (A6) and the control module (A3), release the ground s...2507
4 Support the control module, remove the two remaining nuts (A2 and A5) and remove the electronic...2507
1 Fit the electronic control module. Retain with four nuts, ensure that the ground strap is fitte...2507
2 Fit the connectors (A1 and A4) and retain with Allen screws. Tighten the screws to a torque of ...2507
3 Connect the electrical power supply...2507
Engine timing...2508
To check Operation 8-2...2508
Special tools...2508
Description...2508
Part number...2508
1 With the engine switched off and electrically isolated, remove the rocker cover, Operation 3-1...2508
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt...2508
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing b...2508
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind ...2508
5 Attach a plunger clock and set the plunger on the top face of the rocker lever of the number on...2509
6 Rotate the engine in the normal direction of rotation until the timing bolt can again enter the...2509
7 Repeat step 6 to ensure that a consistent reading is obtained...2509
8 If the reading is not within the limits, adjust the position of the adjustable idler gear to ad...2509
Aspiration system...2510
General information...2510
Exhaust manifold...2511
To remove and to fit Operation 9-1...2511
Special tools...2511
Consumable products...2511
Description...2511
Part number...2511
Description...2511
Part number...2511
1 Remove the turbocharger, Operation 9-2...2511
2 Remove the thermostat housing, Operation 12-10...2511
3 Remove the exhaust shield...2511
4 Remove the nuts and spacers which retain the exhaust manifold and remove the manifold...2511
5 Withdraw the sleeves from the cylinder head...2511
6 Remove the gaskets from the cylinder head...2511
1 Check the condition of all sleeves, studs and nuts. Renew the components if worn or damaged. Ap...2511
2 Fit new gaskets over the studs and install the sleeves. Fit the exhaust manifold, fit the space...2511
3 Fit the thermostat housing, Operation 12-10...2511
4 Fit the turbocharger, Operation 9-2...2511
Turbocharger...2512
To remove and to fit Operation 9-2...2512
1 Disconnect the exhaust pipe from the turbocharger...2512
2 Remove the air duct from between the turbocharger and the air cleaner...2512
3 Disconnect the air duct from between the turbocharger and the charge air cooler...2512
4 Disconnect the oil feed (A2) and oil drain (A1) pipes...2512
5 Use a strap and hoist to support the turbocharger, remove the four bolts which retain the turbo...2512
1 Fit the turbocharger to the exhaust manifold. Apply CV60889 anti-seize compound to the bolts. F...2512
2 Connect the oil feed and oil drain pipes (A2 and A1)...2512
3 Fit the air duct between the turbocharger and the air cleaner...2512
4 Connect the air duct between the turbocharger and the charge air cooler...2512
5 Connect the exhaust pipe...2512
To dismantle and to assemble Operation 9-3...2513
1 Remove turbocharger, Operation 9-2...2513
2 Add temporary alignment marks between the bearing housing and both the compressor housing and t...2513
3 Loosen the nuts on the clamps and separate the compressor housing and the turbine housing from ...2513
4 Check the condition of all components. Renew any worn or damaged components...2513
1 Fit the compressor housing and the turbine housing to the bearing housing and retain with the r...2513
2 Adjust the position of both the compressor and turbine housings until the temporary marks are a...2513
3 Fit the turbocharger, Operation 9-2...2513
Lubrication system...2514
General information...2514
Oil filter and oil filter header...2515
To remove and to fit Operation 10-1...2515
1 Remove the plug (A5) and drain the oil from the oil filter housing...2515
2 Remove the oil filter housing (A3), and remove the oil filter element...2515
3 Remove the four bolts (A1) which connect the oil filter header to the oil cooler...2515
4 Remove the two bolts (A2) which retain the oil filter header on the crankcase...2515
5 Disconnect the turbocharger oil supply pipe from the elbow behind the oil cooler...2515
6 Remove the four bolts which retain the assembly of the elbow and oil filter header on the crank...2515
7 Remove the four bolts to separate the oil filter header from the elbow. Renew the ‘O’ ring seal...2515
1 Ensure that the ‘O’ ring seals are fitted to the elbow. Assemble the elbow and oil filter heade...2516
2 Ensure that the used gasket material has been removed from the mating faces. Fit the assembly t...2516
3 Fit the four bolts (A1) which retain the oil filter header to the oil cooler...2516
4 Connect the turbocharger oil supply pipe and tighten securely...2516
5 Clean the filter housing (A3) and clean the contact face of the filter head. Clean the drain pl...2516
6 Fit a new element into the filter housing, ensure that it engages fully with the guide in the b...2516
7 Fit the housing (A3) onto the filter head and tighten by use of a socket and torque wrench on t...2516
8 Check the amount of engine oil in the sump. If necessary, add more oil of the correct grade and...2516
9 Run the engine and check for leaks. Check again the amount of engine oil in the sump. If necess...2516
Oil filter header...2517
To dismantle and to assemble Operation 10-2...2517
1 Remove the two plugs (A5 and A6) which retain the by-pass valves in the oil filter header (A1)...2517
2 Remove the spring (A3) and the plunger (A2) for the oil cooler by-pass valve. Remove the spring...2517
3 Remove the two small plugs and the adaptor...2517
1 Fit the plunger (A9) and spring (A8) to the oil filter header...2517
2 Fit the plunger (A2) and spring (A3) to the oil filter header...2517
3 Fit the plugs (A5 and A6). Tighten each plug to 100 +/- 15 Nm (74 +/- 11 lbf ft)...2517
4 Fit the adaptor and the two small plugs. Tighten each of them to 25 +/- 5 Nm (18 +/- 4 lbf ft)...2517
Sump...2518
To remove and to fit Operation 10-3...2518
Consumable products...2518
Description...2518
Part number...2518
1 Drain the oil from the sump (A2)...2518
2 Loosen the bolts which retain the sump on the engine. Do not remove the bolts fully, allow them...2518
3 Remove the sump...2518
1 Examine the sump seal and renew if necessary. Ensure that the machined surface of the sump is c...2519
2 Clean the bottom face of the crankcase and also the bottom faces of the flywheel housing and th...2519
3 Apply a bead of RTV silicone sealant, CV60888, at the four positions where the edge of the flyw...2519
4 Fit the sump and tighten the bolts to a torque of 30 Nm (22 lbf ft); use the sequence shown (B)...2519
5 Fill the engine to the correct level with oil of the correct grade and specification. Refer to ...2519
Oil pump...2520
To remove and to fit Operation 10-4...2520
1 Remove the sump, Operation 10-3...2520
2 Remove the oil supply tube (A3) and the strainer and tube (A2)...2520
3 Remove the bolts and remove the oil pump (A4)...2520
1 Fit the oil pump to the crankcase...2520
2 Apply clean engine oil to the ‘O’ ring seals of the tubes...2520
3 Install oil supply tube (A3) and strainer and tube (A2)...2520
4 Fit the sump, Operation 10-3...2520
To dismantle and to assemble Operation 10-5...2521
1 Remove the bolt and washer which retain the gear on the shaft...2521
2 Use a suitable gear puller to remove drive gear (A1) from the shaft. Remove the key from the sh...2521
3 Remove retainer (A5) for the by-pass valve...2521
4 Remove the spring (A4) and the by-pass valve (A3)...2521
5 Remove the cover (A6) from the pump body (A2)...2521
6 Remove the idler gear and drive gear from pump body...2521
1 Apply clean engine oil to the idler gear and drive gear and install the gears in the oil pump b...2521
2 Fit the by-pass valve, the spring and the retainer to the pump body (A2)...2521
3 Fit the key to the shaft...2521
4 Fit the drive gear (A1) to the shaft. Install the washer and bolt which retain the gear. Tighte...2521
Fuel system...2522
General information...2522
Fuel priming pump...2523
To remove and to fit Operation 11-1...2523
1 Remove two bolts (A2) and remove fuel priming pump (A1)...2523
1 Inspect the gasket of the fuel priming pump; fit a new gasket if necessary...2523
2 Fit the fuel priming pump (A1) and retain with the two bolts (A2)...2523
Fuel transfer pump...2524
To remove and to fit Operation 11-2...2524
1 Disconnect the fuel pipes from the fuel transfer pump (A2)...2524
2 Use plugs or caps to seal temporarily all openings to prevent contamination of the fuel system...2524
3 Remove the bolts (A1) and withdraw the fuel transfer pump...2524
1 Check the condition of the ‘O’ ring seal on the fuel transfer pump, renew the seal if it is wor...2524
2 Ensure that the ‘O’ ring seal is fitted correctly to the fuel transfer pump. Apply a small amou...2524
3 Fit the fuel transfer pump (A2) and retain with two bolts (A1)...2524
4 Remove the plugs or caps from the fuel pipe openings and connect the fuel pipes...2524
5 Eliminate air from the fuel system, Operation 11-6...2524
To test Operation 11-3...2525
1 Run the pump at 2940 rev/min. The flow at 650 kPa (94 lb/in2) must be 4,5 litres/min (1.0 UK ga...2525
2 Run the pump at 840 rev/min. The flow at 550 kPa (80 lb/in2) must be 3,0 litres/min (0.66 UK ga...2525
3 Run the pump at 100 rev/min with the inlet to the atmosphere for 10 seconds. The pump must main...2525
Drive for the fuel transfer pump...2526
To remove and to fit Operation 11-4...2526
1 Remove the fuel transfer pump (A2), Operation 11-2...2526
2 Remove four bolts and washers (A1) and withdraw the assembly of the pump drive and housing (A3)...2526
3 Remove the three bolts from the housing (B1) and remove the assembly of the bearings and gear (...2526
4 Remove the ‘O’ ring seal (B3) from the housing...2526
5 Inspect all components, renew any which are worn or damaged...2526
1 Fit the assembly of the bearings and gear (B2) into the pump drive housing (B1)...2526
2 Retain the gear and bearings in the housing with the three bolts...2526
3 Fit a new ‘O’ ring seal (B3) to the housing...2526
4 Insert carefully the assembly of the pump drive and pump drive housing into the gear case. Reta...2526
5 Fit the fuel transfer pump, Operation 11-2...2526
Fuel filter header...2527
To remove and to fit Operation 11-5...2527
1 Remove the fuel priming pump (A2), Operation 11-1...2527
2 Disconnect the fuel pipes (A1, A3, A4 and A5). Fit plugs or caps to all openings to prevent con...2527
3 Remove the filter housings and elements from the fuel filter header...2527
4 Remove the bolts which retain the filter header on the crankcase...2527
1 Fit the filter header to the crankcase...2527
2 Remove any plugs or caps and connect the fuel pipes (A1, A3, A4 and A5)...2527
3 Renew the fuel filter elements in the primary and secondary fuel filter canisters. Use the proc...2527
4 Fit the fuel priming pump, Operation 11-1...2527
5 Eliminate air from the fuel system, Operation 11-6...2527
Low pressure fuel system...2528
How to eliminate air from the fuel system Operation 11-6...2528
1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) un...2528
2 Tighten the union (A1). Operate the hand priming pump until a strong pressure is felt on the pu...2528
3 Start the engine...2528
4 If the engine will not start, allow the starter motor to cool for 2 minutes. Repeat steps 1 and...2528
5 Run the engine with no load until it runs smoothly...2528
Cooling system...2530
General information...2530
Cooling system...2531
To inspect Operation 12-1...2531
1 Check the coolant level in the cooling system...2531
2 Check for leaks in the system...2531
3 Ensure that the air flow through the radiator is not restricted. Check for bent fins in the rad...2531
4 Inspect the drive belts for the fan...2531
5 Check for damage to the fan blades...2531
6 Check for air or combustion gas in the cooling system...2531
7 Inspect the filler cap and check the surface which the filler cap seals against. This surface m...2531
Leakage test Operation 12-2...2532
Special tools...2532
Description...2532
Part number...2532
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the ...2532
2 Ensure that the coolant is at the correct level...2532
3 Attach the pressurizing pump, GE50031, to the radiator and apply pressure until the reading on ...2532
4 Check the radiator for leakage...2532
5 Check all connection points and hoses for leakage...2532
Coolant filler cap...2533
To test Operation 12-3...2533
Special tools...2533
Description...2533
Part number...2533
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the ...2533
2 Carefully inspect the filler cap. Check for damage to the seals and to the sealing surface. Exa...2533
3 Check the opening pressure for the filler cap as follows: fit the filler cap to the pressurizin...2533
4 Apply pressure and check the gauge for the exact pressure which opens the filler cap...2533
5 Compare the reading on the gauge with the correct pressure which should open the filler cap, th...2533
6 Renew the filler cap if it is defective...2533
Radiator...2534
To remove and to fit Operation 12-4...2534
1 Drain the coolant into a suitable container...2534
2 Remove the air duct from between the charge air cooler and the air inlet elbow...2534
3 Remove the coolant pipe from between the thermostat housing and the top of the radiator...2534
4 Remove the fan guards...2534
5 Remove the air duct from between the turbocharger and the base of the charge air cooler...2534
6 Remove the coolant pipe from between the coolant pump elbow and the radiator...2534
7 Remove fasteners which retain the radiator to its base frame...2534
1 Fit the radiator to its base frame...2534
2 Fit the coolant pipe between the coolant pump elbow and the radiator...2534
3 Fit the air duct between the turbocharger and the base of the charge air cooler...2534
4 Fit the fan guards...2534
5 Fit the coolant pipe between the thermostat housing and the top of the radiator...2534
6 Fit the air duct between the charge air cooler and the air inlet elbow...2534
7 Fill the radiator with the correct coolant mixture. Refer to the User’s Handbook...2534
8 Run the engine until it reaches the normal temperature of operation and check for leaks...2534
Fan...2535
To remove and to fit Operation 12-5...2535
1 Switch off the engine and disconnect the electrical power supply...2535
2 Remove the fan guards...2535
3 Remove the bolts which retain the fan on the hub and remove the fan...2535
1 Fit the fan to the hub and retain with the six bolts...2535
2 Fit the fan guards...2535
3 Connect the electrical power supply...2535
Fan drive assembly...2536
To remove and to fit Operation 12-6...2536
1 Remove the fan, Operation 12-5...2536
2 Remove the hub (A1)...2536
3 Loosen the adjustment bolts to release the tension on the alternator belt. Remove the belt and ...2536
4 Release the tension on the fan drive belts and remove the belts...2536
5 Remove the two bolts and cap which retain the pulley (A2) and withdraw the pulley complete with...2536
6 Remove the two nuts and two bolts which retain the fan bearing housing (A4) and remove the hous...2536
1 Fit the fan bearing housing (A4)...2536
2 Fit the pulley (A2) and retain with the cap and two bolts. Tighten the bolts to a torque of 24 ...2536
3 Fit the fan drive belts and adjust the tension as given in Operation 12-7...2536
4 Fit the alternator (A3), fit the alternator belt and adjust the tension as given in Operation 1...2536
5 Fit the hub (A1)...2536
6 Fit the fan, Operation 12-5...2536
Fan drive belts...2537
To check and to adjust the tension Operation 12-7...2537
1 Remove the fan guards...2537
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A1). It should b...2537
3 Loosen the lock nuts on the adjustment bolt (A2), loosen the large lock nut on the belt tension...2537
4 Fit the fan guards and run the engine for 15 minutes. Remove the guards and check again the ten...2537
5 For new fan belts, set the tension to 868 N, which is equivalent to 4,0 mm of movement when a f...2537
6 When the correct tension is obtained, fit the fan guards...2537
To renew Operation 12-8...2538
1 Remove the fan, Operation 12-5...2538
2 Loosen the belt tensioner and remove the old belts. Ensure that the grooves of the pulley are f...2538
3 Fit the fan and tighten the bolts securely. Adjust the fan belts to the correct tension, as giv...2538
Engine oil cooler...2539
To remove and to fit Operation 12-9...2539
1 Drain the coolant from the engine...2539
2 Use a tray to collect any oil which may spill from the oil cooler during its removal...2539
3 Make temporary marks on the coolant duct (A2) and the oil cooler (A1) for correct alignment dur...2539
4 Remove the four bolts which retain the oil cooler (B1) on the oil filter header (B3)...2539
5 Withdrawn the oil cooler from the elbow (B2), take care not to damage the seal...2539
6 Remove the ‘O’ ring seal from the elbow (B2)...2539
1 Clean the core tubes of the oil cooler with a 3,81 mm (0.150 in) diameter rod...2539
2 Check the condition of the ‘O’ ring seals used on the oil cooler and the oil filter header. Ren...2539
3 Ensure that the ‘O’ ring seals are fitted to the oil filter header...2539
4 Fit the ‘O’ ring seal over the elbow (B2). Apply clean engine oil on the seal...2539
5 Align the oil cooler with the elbow and slide the oil cooler over the elbow. Fit the four bolts...2539
6 Fit an ‘O’ ring seal to the coolant duct (A2) and fit the duct to the oil cooler. Fit the four ...2539
7 Fill the cooling system with the correct coolant mixture. Refer to the User’s Handbook...2539
8 Check the amount of lubricating oil in the sump. Add lubricating oil of the correct grade, if n...2539
9 Clean away any oil or coolant which has been spilled...2539
Thermostats and thermostat housing...2540
To remove and to fit Operation 12-10...2540
1 Drain the coolant until the level is below the thermostat housing (A1)...2540
2 Disconnect the cable (A3) from the coolant temperature sensor...2540
3 Release the hose clips (A2) and disconnect the pipe and hose from the top of the unit...2540
4 If the thermostats are to be removed, loosen all five bolts of the thermostat housing; then rem...2540
5 Lift carefully the assembly to separate it from the coolant bobbin (A5) at its base...2540
1 Clean thoroughly both parts of the assembly and check the condition of the lip-type seals. Rene...2541
2 Fit the new thermostats. Ensure that the new thermostats are fitted correctly. Fit a new ‘O’ ri...2541
3 Ensure that the mating face on the cylinder head is clean. Fit new seals to the coolant bobbin ...2541
4 Connect the hose to the top of the housing and tighten the hose clip...2541
5 Connect the cable (A3) to the coolant temperature sensor...2541
6 Fill the coolant system to the correct level with the approved coolant mixture...2541
7 Operate the engine until it reaches the normal temperature of operation and check for leaks. St...2541
To test the thermostats Operation 12-11...2542
1 Remove the thermostats from the engine...2542
2 Heat water in a suitable container until the temperature is 98 C (208 F). Stir the water to e...2542
3 Suspend the thermostat in the container of water. The thermostat must be below the surface of t...2542
4 Ensure that the water is maintained at the correct temperature for ten minutes...2542
5 After ten minutes, remove the thermostat. Immediately check the distance that the thermostat ha...2542
Coolant temperature sensor...2543
To test Operation 12-12...2543
Special tools...2543
Description...2543
Part number...2543
1 When the engine is cool, release the coolant filler cap to relieve any pressure...2543
2 Remove one of the two plugs (A1) and install the special thermometer, GE50032. A temperature in...2543
3 Start the engine and run the engine until the temperature reaches the desired range according t...2543
Pointer...2543
position...2543
Test...2543
thermometer C...2543
Test...2543
thermometer F...2543
4 If the temperature sensor is renewed, do not attempt to disconnect the leads from the unit. Dis...2543
Coolant pump...2544
To remove and to fit Operation 12-13...2544
1 Drain the coolant from the engine into a suitable container for storage or disposal...2544
2 Remove the thermostat housing, Operation 12-10...2544
3 Remove the oil cooler, Operation 12-9...2544
4 Remove four bolts (A1) and the elbow (A2)...2544
5 Check the condition of the ‘O’ ring seal (B1), discard the seal if it is worn or damaged. Remov...2544
1 Fit the coolant pump to the gear case, ensure that the gear engages correctly. Tighten the bolts...2544
2 If necessary, fit a new ‘O’ ring seal (B1). Fit the elbow (A2) and retain with four bolts (A1)...2544
3 Fit the oil cooler, Operation 12-9...2544
4 Fit the thermostat housing, Operation 12-10...2544
5 Fill the coolant system to the correct level with the specified coolant mixture. Refer to the U...2544
To dismantle and to assemble Operation 12-14...2545
1 Remove the bolt (A15) and washer (A14). Use a suitable puller to remove the impeller (A11) from...2545
2 Remove the spring and seal (A13) from the shaft...2545
3 Remove the four bolts (A6) from the retainer (A7) and remove the ‘O’ ring seal (A9) from the ho...2545
4 Remove the gear and shaft assembly (A8). Remove the bolt (A4) and retainers (A3 and A7) from th...2545
5 Use a press to remove the shaft (A16) from the gear. Remove the bearing (A1), the spacer if fit...2545
6 Remove the lip-type seal (A12) from the housing...2545
1 Ensure that the shaft and the seal counter bore in the pump housing are clean...2546
2 Fit the bearing (A1), the spacer if relevant, and the second bearing (A2) to the shaft (A16)...2546
3 Fit the retainer (A7) and gear (A8) to the shaft assembly. Fit the second retainer (A3) and the...2546
4 Fit a new lip-type seal (A12) into the housing (A10). The seal must be fitted with the lip towa...2546
5 Fit a new ‘O’ ring seal (A9) to the housing...2546
6 Install the gear and shaft assembly in the housing. Fit the bolts (A6) which hold the retainer ...2546
7 Separate the spring from the seal assembly (A13). Use hand pressure to install the seal on the ...2546
8 Fit the impeller (A11) to the shaft and retain with the washer (A14) and bolt (A15). Tighten th...2546
9 Fit the coolant pump, Operation 12-13...2546
To test the pressure of the coolant pump Operation 12-15...2547
Special tools...2547
Description...2547
Part number...2547
1 To check that the coolant pump is operating correctly, the outlet pressure can be measured...2547
2 Remove the plug (A1) from the coolant manifold and connect the pressure gauge, GE50033, to the ...2547
3 Start the engine and run the engine until the normal temperature of operation is obtained...2547
4 Make a note of the reading on the pressure gauge. The pressure supplied by the coolant pump sho...2547
Flywheel and housing...2548
General information...2548
Flywheel...2549
To remove and to fit Operation 13-1...2549
1 Remove two of the flywheel bolts from horizontally opposite sides of the flywheel and insert tw...2549
2 Remove the bolts which remain and withdraw the flywheel from the crankshaft. Fit a suitable sli...2549
3 Remove the flywheel and remove the guide studs...2549
4 Remove the gear ring from the flywheel if necessary...2549
1 If the gear ring has been removed, heat the ring in an oven to a maximum temperature of 315 C ...2549
2 Fit suitable guide studs to bolt holes at horizontally opposite sides of the flywheel. Ensure t...2549
3 Attach a sling to the flywheel and use a hoist to locate the flywheel on the guide studs. Ensur...2549
4 Remove the sling and slide the flywheel up to the crankshaft...2549
5 Apply clean engine oil to the threads of the bolts which retain the flywheel and fit 10 of the ...2549
Flywheel housing...2550
To remove and to fit Operation 13-2...2550
Consumable products...2550
Description...2550
Part number...2550
1 Remove the flywheel, Operation 13-1...2550
2 Remove the crankshaft rear seal and wear sleeve, Operation 5-3...2550
3 Remove the starter motor, Operation 14-1...2550
4 Remove the sump, Operation 10-3...2550
5 Use a suitable hoist to support the flywheel housing and remove the bolts (A1 to A24) which ret...2550
6 Remove the flywheel housing from the dowels in the crankcase. The weight of the flywheel housin...2550
1 Clean thoroughly the contact surfaces of the crankcase and flywheel housing...2551
2 Fit the two dowels (B2 and B3) if they have been removed from the crankcase. They must protrude...2551
3 Apply a bead of liquid gasket, CH10879, to the area shown (B1)...2551
4 Attach a suitable hoist and fit the flywheel housing to the crankcase. Fit the bolts which reta...2551
5 Tighten the flywheel housing bolts as follows:...2551
6 Fit the sump, Operation 10-3...2551
7 Fit the starter motor, Operation 14-1...2551
8 Fit a new crankshaft rear seal and wear sleeve, Operation 5-3...2551
9 Fit the flywheel, Operation 13-1...2551
Electrical equipment...2552
General information...2552
Starter motor...2553
To remove and to fit Operation 14-1...2553
1 Disconnect the batteries before any service work is attempted...2553
2 Disconnect the wiring loom from the starter motor assembly (A2)...2553
3 Fasten a hoist to the starter motor. Remove the three bolts (A1) which retain the starter motor...2553
1 Use a hoist to support the starter motor. Fit the starter motor to the flywheel housing. Retain...2553
2 Connect the wiring loom to the starter motor. If the engine earth strap is connected to the sta...2553
3 Connect the batteries...2553
Alternator...2554
To remove and to fit Operation 14-2...2554
1 Disconnect the batteries before any service work is attempted...2554
2 Remove the access panel in the fan guard...2554
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley ...2554
4 Disconnect the wiring loom from the alternator...2554
5 Remove the bolts (A3 and A4) and remove the alternator...2554
1 Fit the alternator and retain with the pivot bolt (A3) and the adjustment link bolt (A4). Do no...2554
2 Fit the alternator drive belt over the alternator pulley and set the tension as given in Operat...2554
3 Connect the wiring loom to the alternator...2554
4 Fit the access panel to the fan guard...2554
5 Connect the batteries...2554
To check and to adjust the tension of the alternator belt Operation 14-3...2555
1 Remove the access panel in the fan guard and proceed as follows...2555
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A5). It should b...2555
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley ...2555
4 Fit the access panel to the fan guard and run the engine for 15 minutes. Remove the access pane...2555
5 If a new alternator belt is fitted, set the tension to 400 N, which is equivalent to 2,5 mm of ...2555
6 When the correct tension is obtained, fit the access panel to the fan guard...2555
To renew the alternator belt Operation 14-4...2556
1 Remove the fan, Operation 12-5...2556
2 Loosen the adjustment bolts to release the tension on the alternator belt and remove the old be...2556
3 Fit the fan, Operation 12-5...2556
4 Adjust the alternator belt to the correct tension, Operation 14-3...2556
Auxiliary equipment...2558
General information...2558
Oil sample valve...2558
Special tools...2560
List of special tools...2560
Tool number...2560
Description...2560
Illustration...2560
TSD3457E2 - Diagnostic Manual (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engine))...2568
TSL4247 - Diagnostic Manual (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engine))...2724
Contents...2728
1 General information...2732
Introduction...2732
Safety precautions...2733
2 Electronic system overview...2734
System operation...2734
Electronic controls...2734
Engine governor...2734
Timing considerations...2734
Fuel injection...2734
Engine monitoring...2735
Fuel temperature monitoring...2736
Self diagnostics...2736
Effect of diagnostic codes on engine performance...2736
Current totals stored in the ECM...2737
Programmable parameters...2737
Passwords...2737
Engine component diagram...2738
OEM connection diagram...2739
Sensor and connector location diagram...2740
Engine wiring diagram...2741
Machine wiring diagram (all options)...2742
Electrical connectors and functions...2743
Service tools and diagnostics...2744
Required service tools...2745
Optional service tools...2746
Service tool illustrations...2747
3 Programming parameters...2748
Connecting the TIPSS-EST...2748
Passwords...2750
Programming a new ECM...2751
Programming a Personality Module using flash programming...2754
ECM date/time clock...2755
ECM diagnostic clock...2755
Injector codes...2756
TIPSS-EST manual cylinder cutout test...2756
Programming parameters...2757
System configuration parameters...2757
Customer specified parameters...2759
4 Troubleshooting without a diagnostic code...2762
Introduction...2762
P-401 - Engine will not crank...2763
P-402 - Engine cranks but will not start...2764
P-403 - Engine misfires, runs rough or is unstable...2765
P-404 - Low power/poor or no response to throttle...2766
P-405 - Intermittent engine shutdowns...2767
P-406 - Intermittent low power or power cutouts...2768
P-407 - Electronic service tool will not communicate with the ECM...2769
P-408 - ECM will not accept factory passwords...2770
P-409 -Excessive black smoke...2771
P-410 - Excessive white smoke...2772
P-411 - Engine cannot reach correct rev/min...2773
P-412 - Poor acceleration or response...2774
P-413 - Poor fuel consumption...2775
P-414 - Too much vibration...2776
P-415 - Noise coming from cylinder...2777
P-416 - Excessive valve clearance...2778
P-417 - Valve rotocoil or spring lock is free...2779
P-418 - Mechanical noise (knock) in engine...2780
P-419 - Oil in cooling system...2781
P-420 - Fuel in cooling system...2782
P-421 - Coolant in lubricating oil...2783
P-422 - Fuel dilution of lubricating oil...2784
P-423 - Engine has early wear...2785
P-424 - Engine has low oil pressure...2786
P-425 - Engine uses too much lubricating oil...2787
P-426 - Engine coolant is too hot...2788
P-427 - Oil at the exhaust...2789
P-428 - Engine has a fuel supply problem...2790
P-429 - Indicator lamp not functioning correctly...2791
P-430 - Inlet air manifold temperature is too high...2792
P-431 - Engine has a high fuel temperature...2793
5 Troubleshooting with an event code...2794
General information...2794
Event codes...2795
E36-2 - Low coolant temperature Action Alert...2796
E162-1 - High boost pressure Warning...2797
E162-2 - High boost pressure Action Alert...2797
E360-1 - Low oil pressure Warning...2798
E360-2 - Low oil pressure Action Alert...2798
E360-3 - Low oil pressure Shutdown...2798
E361-1 - High coolant temperature Warning...2799
E361-2 - High coolant temperature Action Alert...2799
E361-3 - High coolant temperature Shutdown...2799
E362-1 - Engine overspeed Warning...2800
E362-2 - Engine overspeed Action Alert...2800
E362-3 - Engine overspeed Shutdown...2800
E363-1 - High fuel temperature Warning...2801
E363-1 - High fuel temperature Action Alert...2801
E368-1 - High inlet air temperature Warning...2802
E368-2 - High inlet air temperature Action Alert...2802
6 Troubleshooting with a diagnostic code...2804
Diagnostic codes...2804
Diagnostic terminology...2806
Quick reference for ECM diagnostic codes...2807
7 Functional tests...2810
General information...2810
Connectors...2810
Test 1 - Inspecting electrical connectors...2811
Test 2 - Electrical power supply to the ECM...2816
Test 3 - Analogue sensor open or short circuit test...2819
Test 4 - ECM Status indicator output circuit test...2828
Test 5 - +5 V Sensor voltage supply circuit test...2833
Test 6 - PWM desired speed setting circuit test...2838
Test 7 - Perkins Data Link circuit test...2845
Test 8 - Engine speed/timing circuit test...2852
Test 9 - Engine speed/timing calibration...2860
Test 10 - Injector solenoids circuit test...2864
8 Glossary...2874
Glossary of terms...2874
Quick reference for ECM diagnostic codes...2726
Perkins 2000, 2200, 2300, 2500, 2800, Eagle Series Engines Repair Service Manual
