400c.pdf

SENR9973-01September 2007

Disassembly andAssembly400C Industrial EngineHB (Engine)HD (Engine)HH (Engine)HL (Engine)HM (Engine)HN (Engine)HP (Engine)HR (Engine)

This document has been printed from SPI². Not for Resale

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

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

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

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

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

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

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

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

When replacement parts are required for thisproduct Perkins recommends using Perkins replacement parts.Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.


SENR9973-01 3Table of Contents

Table of Contents

Disassembly and Assembly Section

Fuel Priming Pump - Remove ................................. 4Fuel Priming Pump - Install ..................................... 4Fuel Filter Base - Remove ..................................... 5Fuel Filter Base - Install ......................................... 6Fuel Injection Lines - Remove and Install .............. 7Fuel Shutoff Solenoid - Remove and Install .......... 9Fuel Injection Pump - Remove ............................ 10Fuel Injection Pump - Install ................................. 11Fuel Injector - Remove ........................................ 12Fuel Injector - Install ............................................ 12Turbocharger - Remove and Install ..................... 13Exhaust Manifold - Remove and Install ............... 15Inlet and Exhaust Valve Springs - Remove andInstall ................................................................... 17Inlet and Exhaust Valves - Remove and Install .... 19Engine Oil Line - Remove and Install ................... 21Engine Oil Cooler - Remove and Install ............... 23Engine Oil Relief Valve - Remove and Install ....... 24Engine Oil Pump - Remove .................................. 24Engine Oil Pump - Install ...................................... 26Water Pump - Remove ......................................... 28Water Pump - Install ............................................. 30Water Temperature Regulator Housing - Remove andInstall .................................................................. 31Water Temperature Regulator - Remove and Install............................................................................. 32Flywheel - Remove ............................................... 35Flywheel - Install ................................................... 36Crankshaft Rear Seal - Remove ........................... 37Crankshaft Rear Seal - Install ............................... 37Flywheel Housing - Remove and Install .............. 39Crankshaft Pulley - Remove and Install ............... 42Crankshaft Front Seal - Remove .......................... 43Crankshaft Front Seal - Install .............................. 43Housing (Front) - Remove .................................... 44Housing (Front) - Disassemble ............................. 45Housing (Front) - Assemble .................................. 47Housing (Front) - Install ........................................ 50Crankcase Breather - Remove and Install ........... 51Valve Mechanism Cover - Remove and Install ..... 54Rocker Shaft and Pushrod - Remove ................... 55Rocker Shaft - Disassemble ................................ 56Rocker Shaft - Assemble ..................................... 57Rocker Shaft and Pushrod - Install ....................... 59Cylinder Head - Remove ...................................... 60Cylinder Head - Install .......................................... 61Lifter Group - Remove and Install ......................... 63Camshaft - Remove .............................................. 64Camshaft - Disassemble ....................................... 65Camshaft - Assemble ........................................... 66Camshaft - Install .................................................. 66Engine Oil Pan - Remove and Install ................... 67Pistons and Connecting Rods - Remove .............. 68Pistons and Connecting Rods - Disassemble ....... 69Pistons and Connecting Rods - Assemble ........... 71Pistons and Connecting Rods - Install .................. 73Connecting Rod Bearings - Remove .................... 74

Connecting Rod Bearings - Install ........................ 75Crankshaft Main Bearings - Remove .................... 76Crankshaft Main Bearings - Install ........................ 77Crankshaft - Remove ............................................ 78Crankshaft - Install ................................................ 80Bearing Clearance - Check ................................... 81Coolant Temperature Switch - Remove andInstall ................................................................... 82Engine Oil Pressure Switch - Remove and Install............................................................................. 84Glow Plugs - Remove and Install ......................... 86V-Belts - Remove and Install ................................ 86Fan - Remove and Install ..................................... 87Alternator - Remove and Install ........................... 91Electric Starting Motor - Remove and Install ..... 101

Index Section

Index ................................................................... 103


4 SENR9973-01Disassembly and Assembly Section

Disassembly and AssemblySection

i02186288

Fuel Priming Pump - Remove

Removal Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Dispose of all fluids according to local regulations andmandates.

g00824616Illustration 1

Typical example

1. Loosen the hose clamps and remove the two fuellines from the fuel priming pump (1). Note thepositions of the fuel inlet and the fuel outlet forinstallation.

2. Install suitable plugs into the fuel lines in order toprevent contamination.

3. Remove the two setscrews (4) that fasten the fuelpriming pump (1) to the cylinder block.

Note: The fuel priming pump can be oriented in twopositions. Before removing the fuel priming pump (1)from the cylinder block, note the orientation of theflange (2) of the fuel priming pump (1) for assembly.

4. Remove the fuel priming pump (1) and the O-ring(3). Discard the O-ring.

Note: In order to remove the fuel priming pumpfrom the engine, it may be necessary to rotate thecrankshaft until the operating plunger of the fuelpriming pump is not under pressure.

i02186279

Fuel Priming Pump - Install

Installation Procedure






SENR9973-01 5Disassembly and Assembly Section


Typical example

1. Clean the mating surfaces of the fuel primingpump on the cylinder block and clean the flange(2) of the fuel priming pump.

Note: Ensure that the camshaft lobe for the fuelpriming pump is at minimum lobe lift before the fuelpriming pump is installed. The fuel priming pumpcan be oriented in two positions. Ensure that the fuelpriming pump is oriented in the correct position.

2. Install a new O-ring (3) to the fuel priming pump(1).

3. Lubricate the operating plunger of the fuel primingpump (1) with clean engine oil.

4. Install the fuel priming pump (1) to the engine.Ensure that the operating plunger is positionedcorrectly on the camshaft lobe.

5. Install the two setscrews (4) that fasten the fuelpriming pump (1) to the cylinder block. Tighten thesetscrews to a torque of 6 N·m (4.5 lb ft).

6. Loosely install the hose clamps to the fuel lines.Connect the appropriate fuel lines to the fuel inletand the fuel outlet of the fuel priming pump (1).Tighten the hose clamps.

Note: The fuel inlet for the fuel priming can berotated 360 degrees by loosening setscrew (5). Thefuel inlet is adjustable in 15 degree increments. Ifadjustment is made to the position of the fuel inlet,tighten setscrew (5) to a torque of 2.5 N·m (22 lb in).

7. Prime the fuel system. Refer to Testing andAdjusting, “Fuel System - Prime” for additionalinformation.

i02186242

Fuel Filter Base - Remove

Removal Procedure



NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.


g01118406Illustration 3Typical example

1. Disconnect the fuel lines (1) and (2). Inspect thecondition of the rubber olives (not shown) that sealthe fuel lines. If the olives are damaged or worn,use new parts for replacement.



Note: Put identification marks on all the fuel lines forinstallation purposes. Plug all the fuel lines and allthe ports in the fuel filter base. This helps preventfluid loss, and this helps to keep contaminants fromentering the system.

2. Remove the fuel filter element (4). Refer toOperations and Maintenance Manual, “FuelSystem Filter - Replace”.

3. If necessary, remove the plugs (5), the washers(6) and the inner seals (7).

4. Remove the setscrews (8) and the nuts (notshown).

5. Remove the fuel filter base (3) from the engine.

i02186227

Fuel Filter Base - Install





Typical example

1. Align the fuel filter base (3) with the mountingbracket. Install the bolts (8) and nuts (not shown).Tighten the nuts to a torque of 22 N·m (16.2 lb ft).

Note: Some fuel filters are installed by the OEM andtorques for the mounting fasteners may vary. Checkwith the OEM Installation Manual for the correcttorque setting.

2. If necessary, install the fuel filter element (4)to the fuel filter base (3). Refer to Operationsand Maintenance Manual, “Fuel System Filter -Replace”.

3. If necessary, install new olives onto the fuel lines.Connect the fuel lines (1) and (2) to the fuel filterbase (3). Tighten the nuts on the fuel lines (1) and(2) to a torque of 9 N·m (6.6 lb ft).

4. If necessary, install new inner seals (7) to the fuelfilter base (3).

Install new washers (6) onto the plugs (5) andinstall the plugs (5) to the fuel filter base (3).Tighten the plugs (5) to a torque of 22.5 N·m(16.6 lb ft).



End By:

a. Remove the air from the fuel system. Referto Operations and Maintenance Manual, “FuelSystem - Prime”.

i02801636

Fuel Injection Lines - Removeand Install

Removal Procedure





NOTICEDo not let the tops of fuel injectors turn when the fuelline nuts are loosened or tightened.

The nozzles will be damaged if the top of the injectorturns in the body.

The engine will be damaged if a defective fuel injectoris used because the shape of fuel (spray pattern) thatcomes out of the nozzle will not be correct.

Note: The removal procedure is similar for the twocylinder, the three cylinder and the four cylinderengines. The illustrations show the 404C-22 and404C-22T engines.


404C-22 and 404C-22T engines

1. Disconnect the union nuts (1) for the fuel injectionlines (2) from the fuel injectors.

2. Disconnect the union nuts (1) for the fuel injectionlines (2) from the fuel injection pump.

3. Remove the fuel injection lines (2) from the engineas a unit.

Note: Place identification marks on all tubeassemblies for installation. Plug all tube assembliesin order to prevent contamination.

4. Install suitable plastic plugs to the outletconnections of the fuel injection pump.

5. The 403C-15, 403C-17, 404C-22 and 404C-22Tengines have a rigid fuel return line.

For engines with a rigid fuel return line, removethe banjo bolt (4) from the fuel return line (3).Remove the washers (8) from the fuel return line(3). Discard the washers.

The 402C-05, 403C-07, 403C-11 and 404C-15engines have a flexible fuel return hose.

For engines with a flexible fuel return hose,disconnect the union nut from the banjo piece.





6. Remove the nut (5) from the fuel injectors (7).

7. Remove the fuel return line (3) from the engineand remove washers (6) from the fuel injectors(7). Discard the washers.

8. Install suitable plastic plugs to the fuel injectors.




NOTICEDo not let the tops of fuel injectors turn when the fuelline nuts are loosened or tightened.

The nozzles will be damaged if the top of the injectorturns in the body.

The engine will be damaged if a defective fuel injectoris used because the shape of fuel (spray pattern) thatcomes out of the nozzle will not be correct.

Note: The installation procedure is similar for thetwo cylinder, the three cylinder and the four cylinderengines. The illustrations show the 404C-22 and404C-22T engines.

g00824793Illustration 7404C-22 and 404C-22T engines

1. Remove the plastic plugs from the fuel injectors(7). Install new washers (6) to the fuel injectors(7) and install the fuel return line (3) to the fuelinjectors.

Note: The washers (6) have two small holes.

2. Install the nuts (5) to the fuel injectors (7).

3. The 403C-15, 403C-17, 404C-22 and 404C-22Tengines have a rigid fuel return line.

For engines with a rigid fuel return line, install newwashers (8) to the fuel return line (3) and install thebanjo bolt (4) to the fuel injection pump. Tightenthe banjo bolt (4) to a torque of 7 N·m (5.2 lb ft).

The 402C-05, 403C-07, 403C-11 and 404C-15engines have a flexible fuel return hose.

For engines with a flexible fuel return hose,connect the fuel return hose to the banjo pieceand tighten the union nut.

4. Tighten the nuts (5) to a torque of 27 N·m (20 lb ft).





5. Remove the plastic plugs from the fuel injectionlines (2) and remove the plastic plugs from theoutlet connections of the fuel injection pump.Install the fuel injection lines to the engine as aunit.

6. Connect the fuel injection lines (2) to the fuelinjection pump.

7. Connect the fuel injection lines (2) to the fuelinjectors (7).

8. For the 402C-05 and 403C-07 engines, tightenthe union nuts (1) to a torque of 20 N·m (15 lb ft).

For the 403C-11, 403C-15,403C-17, 404C-15,404C-22 and 404C-22T engines, tighten the unionnuts (1) to a torque of 23 N·m (17 lb ft).

9. Prime the fuel system. Refer to Testing andAdjusting, “Fuel System - Prime” for moreinformation.

Note: If new fuel injection lines have been installed,do not make any adjustments to the engine controls.Check the maximum engine speed at no load. Referto Testing and Adjusting, “Engine Speed - Check”for more information.

i02207974

Fuel Shutoff Solenoid -Remove and Install

Removal Procedure






1. Disconnect electrical connections (3) to the fuelshutoff solenoid (1). Mark all connections for laterinstallation.

2. Remove fuel shutoff solenoid (1) from the fuelinjection pump housing by rotating the fuel shutoffsolenoid in a counterclockwise direction.

3. Remove the O-ring (2) from fuel shutoff solenoid(1).







1. Check the condition of O-ring (2). If the O-ring isworn or damaged use a new part for replacement.

2. Install fuel shutoff solenoid (1) into the fuelinjection pump housing by rotating the fuel shutoffsolenoid in a clockwise direction. Tighten the fuelshutoff solenoid to a torque of 17.5 N·m (12.9 lb ft).

3. Reconnect electrical connection (3) to fuel shutoffsolenoid (1) before you operate the engine.

i02797470

Fuel Injection Pump - Remove

Removal ProcedureStart By:

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

b. Remove the fuel shutoff solenoid. Refer toDisassembly and Assembly, “Fuel ShutoffSolenoid - Remove and Install”.





Note: The removal procedure is similar for the twocylinder, the three cylinder and the four cylinderengines. The illustrations show the four cylinderengine.


Typical example


1. Remove the setscrews (4) and the nuts (2) thatfasten the fuel injection pump to the cylinder block.

Note: If the fuel rack control (5) has not been movedaway from the recess of the stop solenoid, damagemay occur.



2. Carefully raise the fuel injection pump (1) fromthe cylinder block and remove the clip (7) thatconnects the link (6) to the fuel rack control (5).

3. Remove the fuel injection pump (1) from thecylinder block.

4. Remove the shims (3) from the mounting face ofthe cylinder block.

Note: Record the thickness of each shim and thenumber of shims for reassembly. The fuel injectiontiming is determined by the thickness of the shimpack that is between the fuel injection pump andthe mounting face on the cylinder block. For moreinformation on the fuel injection pump, refer toSpecifications, “Fuel Injection Pump”.

i02801637

Fuel Injection Pump - Install






Note: The installation procedure is similar for thetwo cylinder, the three cylinder and the four cylinderengines. The illustrations show the four cylinderengine.

1. Clean the mounting face of the fuel injection pumpon the cylinder block. Clean the mating surface ofthe fuel injection pump.


2. Install the correct thickness and the correctnumber of shims (3) on the mounting face ofthe cylinder block. Refer to Specifications, “FuelInjection Pump”.


Typical example

3. Position the fuel injection pump (1) close to themounting face of the cylinder block, and connectthe link (6) and the fuel rack control (5) with theclip (7).

4. Put the fuel injection pump (1) in position on themounting face of the cylinder block.

5. Install the setscrews (4) and the nuts (2) thatfasten the fuel injection pump to the cylinder block.

For 402C-05, 403C-07, 403C-11 and 404C-15engines, tighten the setscrews (4) and the nuts (2)to a torque of 6 N·m (53 lb in).

For 403C-15, 403C-17, 404C-22 engines and404C-22T engines, tighten the setscrews (4) andthe nuts (2) to a torque of 15 N·m (11 lb ft).



End By:

a. Install the fuel shutoff solenoid. Refer toDisassembly and Assembly, “Fuel ShutoffSolenoid - Remove and Install”.

b. Install the fuel injection lines. Refer to Disassemblyand Assembly, “Fuel Injection Lines - Removeand Install”.

i02801638

Fuel Injector - Remove


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






Typical example

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

2. Remove the seat washers (2) from the cylinderhead. Discard the old seat washers.

Note: 402C-05 and 403C-07 engines have two seatwashers. The seat washers are different diameters.403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and404C-22T engines have one seat washer.

3. Cap all openings or plug all openings immediatelyafter disassembly.

i02801639

Fuel Injector - Install







Typical example

1. Clean the injector bore in the cylinder head.Ensure that no debris enters the cylinder head.Clean the threads on the body of the injector.

2. Install new seat washers (3) into the injector borein the cylinder head.

Note: 402C-05 and 403C-07 engines have two seatwashers. The seat washers are different diameters.403C-11, 403C-15, 403C-17, 404C-15, 404C-22 and404C-22T engines have one seat washer.

3. Apply a bead of 1861117 POWERPART UniversalJointing Compound (2) to the first two threads ofthe injector that engage into the cylinder head.The bead of Universal Jointing Compound shouldhave a diameter of 2 mm (0.08 inch) and a lengthof 6 mm (0.25 inch).

Note: Ensure that the universal jointing compounddoes not cover the surface of the fuel injector bodybelow the threads.

4. Install the fuel injector (1) into the cylinder head.Use a deep socket to tighten the fuel injector to atorque of 64 N·m (47 lb ft).

Note: If a new fuel injector has been installed, do notmake any adjustments to the engine controls. Referto Testing and Adjusting, “Engine Speed - Check”for more information.

End By:

a. Install the fuel injection lines. Refer to Disassemblyand Assembly, “Fuel Injection Lines - Removeand Install”.

i02186260

Turbocharger - Remove andInstall

Removal procedure






1. Clean the outer surfaces of the turbocharger (1).

2. Loosen the hose clamps (4). Remove the air inlethose (5).




3. Remove the exhaust pipe (not shown) from theexhaust elbow (21). Refer to the OEM providedinformation for the correct procedure in order toremove the exhaust pipe.

4. Remove the setscrews (15) and remove thesupport bracket for the turbocharger (16). Notethe position of the support bracket for installation.

5. Remove the setscrews (22). Remove the exhaustelbow (21) from the turbocharger (1). Removethe gasket for the exhaust elbow (20) from theturbocharger. Discard the gasket.

6. Place a suitable container below the turbocharger(1) in order to collect any spillage of oil.

7. Remove the banjo bolt (3). Remove the oil supplytube assembly (8). Remove the washers (2)from the turbocharger. Discard the washers. Ifnecessary, remove the setscrews (not shown)for the tube clips (6). Remove the setscrews (7).Remove the oil supply tube assembly (8) from thecylinder block. Remove the O-ring (9). Discardthe O-ring.

8. Remove the setscrews (13). Remove the oildrain tube assembly (11) from the turbocharger.Remove the joint (14) and discard the joint. Ifnecessary, remove the setscrews (12) and removethe oil drain tube assembly (11) from the cylinderblock. Remove the joint (10). Discard the joint.

9. Remove the nuts (19) and the washers (18).Remove the turbocharger (1) from the exhaustmanifold. Remove the turbocharger gasket (23)from the exhaust manifold. Discard the gasket.If necessary, remove the studs (17) from theexhaust manifold.

Note: Do not use the actuator rod of the wastegateto lift the turbocharger.

10. Inspect the turbocharger for damage. If theturbocharger is damaged use a new part forreplacement. Refer to Testing and Adjusting,“Wastegate - Test”.

11. Install suitable plastic plugs into the oil supplyand into the oil drain ports of the turbocharger (1).Install suitable plastic covers to the inlet and to theoutlet of the turbocharger. Install suitable plasticplugs to the oil supply tube assembly (8) and tothe oil drain tube assembly (11).

Installation procedure



1. Remove all of the plastic plugs from all of the portsof the turbocharger (1). Clean the mating surfacesof the exhaust manifold and the turbocharger.


2. Ensure that all of the turbocharger inlet and outletports are clean and free from restrictions. Theturbocharger shaft must rotate freely.



3. If the studs (17) were previously removed, installthe studs into the exhaust manifold. Install a newgasket (23) over the studs (17).

Note: Do not use any sealant on the gasket (23).

Note: Do not use the actuator rod of the wastegateto lift the turbocharger (1).

4. Position the turbocharger (1) onto the exhaustmanifold.

5. Install the washers (18) and install the nuts (19).Tighten the nuts to a torque of 25 N·m (18 lb ft).

6. Lubricate the bearing housing of the turbocharger(1) with clean engine oil. Apply the lubricantthrough the oil supply port (24).


7. Clean the oil supply tube assembly (8) and the oildrain tube assembly (11). Inspect the oil supplytube assembly and the oil drain tube assembly. Ifnecessary, replace the tube assemblies.

8. Position a new joint (14) and the oil drain tubeassembly (11) onto the bottom of the turbocharger.Install the setscrews (13). Tighten the setscrewsto a torque of 10 N·m (7 lb ft).

9. If necessary, position a new joint (10) and the oildrain tube assembly (11) onto the cylinder block.Install the setscrews (12). Tighten the setscrewsto a torque of 10 N·m (7 lb ft).

10.Position the new washers (2) and the oil supplytube assembly (8) onto the turbocharger (1).Install the banjo bolt (3). Tighten the banjo bolt toa torque of 18 N·m (13 lb ft).

11. If necessary, install a new O-ring (9) and the oilsupply tube assembly (8) to the cylinder block.Install the setscrews (7). Tighten the setscrews toa torque of 10 N·m (7 lb ft).

12. If necessary, install the spacer (not shown) andinstall the setscrews (not shown) to the tube clips(6). Torque the setscrews to 10 N·m (7 lb ft).

Note: Ensure that the oil supply tube assembly (8)does not come into contact with any other componentwhen the assembly is installed onto the engine.

13.Clean the mating surfaces of the exhaust elbow(21). Position a new gasket (20) and the exhaustelbow (21) on the turbocharger (1). Install thesetscrews (22). Tighten the setscrews to a torqueof 32 N·m (24 lb ft).

14. Install the set screws (15) and install the supportbracket for the turbocharger (16). Tighten thesetscrews to a torque of 25 N·m (18 lb ft).

15.Ensure that the inlet hose (5) is clean and freefrom defects or restrictions. Loosely install thehose clamps (4) to the air inlet hose (5). Installthe air inlet hose to the connection of the inletmanifold and to the inlet of the turbocharger.Tighten the hose clamps.

Note: Do not use oil or grease in order to install theair inlet hose. In order to install a new air inlet hose,lubricate the connection of the inlet manifold andlubricate the inlet of the turbocharger with a solutionof water and 5% soap.

16.Position the exhaust pipe onto the exhaust elbow(21). Refer to the OEM information for the correctprocedure in order to install the exhaust pipe.

i02801640

Exhaust Manifold - Removeand Install

Removal Procedure





Note: The two cylinder, the three cylinder and the fourcylinder engines have different exhaust manifolds.The removal procedure is similar for all models.


1. Loosen the nuts (5) and the setscrews (6).

Note: In order to prevent distortion of the exhaustmanifold, loosen the outer fasteners first.

2. Remove the nuts (5) and the setscrews (6).

Note: Identify setscrews of different lengths sothat the setscrews can be reinstalled in the correctpositions.

3. Remove the exhaust manifold (4) from the cylinderhead (1).

4. Remove the gasket (3) from the cylinder head.

5. Remove any remaining gasket material andcarbon from the cylinder head and the exhaustmanifold. Be careful not to damage the matingsurface on the cylinder head or the mating surfaceon the exhaust manifold.

6. If necessary, remove the exhaust manifold studs(2) from the cylinder head (1).




Note: The two cylinder, the three cylinder and the fourcylinder engines have different exhaust manifolds.The installation procedure is similar for all models.


1. If necessary, install the exhaust manifold studs(2) to cylinder head (1).

2. Install a new exhaust manifold gasket (3) to thecylinder head (1).

Note: Do not use any sealant on the exhaustmanifold gasket.

3. Put the exhaust manifold (4) in position on thecylinder head (1).

4. Install the nuts (5) and the setscrews (6).

Note: Ensure that setscrews with different lengthsare installed in the correct holes.

5. For 402C-05, 403C-07, 403C-11 and 404C-15engines, tighten the nuts (5) and the setscrews (6)to a torque of 10 N·m (89 lb in).

For 403C-15, 403C-17, 404C-22 and 404C-22Tengines, tighten the nuts (5) and the setscrews (6)to a torque of 25 N·m (18 lb ft).

Note: On three cylinder engines, tighten the two innersetscrews first. On four cylinder engines, tighten thefour inner setscrews first. Then tighten the two outersetscrews and the two nuts.



i02187986

Inlet and Exhaust ValveSprings - Remove and Install

Removal ProcedureTable 1

Required Tools

Part Number Part Description Qty

21825666 Valve Spring Compressor 1

27610235 Adapter 1

Start By:

a. Remove the rocker shaft assembly. Refer toDisassembly and Assembly, “Rocker Shaft andPushrod - Remove”.



Note: Before you begin the removal of the valvesprings, refer to Specifications, “Cylinder Head -Valves” and Testing and Adjusting, “Cylinder Head- Inspect” for appropriate information on the valvesprings.

Note: The following procedure should be adoptedin order to remove the valve springs when thecylinder head is still installed onto the cylinder block.Refer to Disassembly and Assembly, “Inlet andExhaust Valves - Remove and Install” for the correctprocedure that should be used to remove the valvesprings from a cylinder head that has been removedfrom the cylinder block.

Note: Ensure that the appropriate piston is at topdead center before the valve spring is removed.Failure to ensure that the piston is at top dead centermay allow the valve to drop into the cylinder bore.

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

Make sure to wear all necessary protective equip-ment.

Follow the recommended procedure and use allrecommended tooling to release the spring force.

NOTICEInstall suitable plugs to the inlet ports of the cylinderhead in order to prevent the entry of loose parts intothe engine.


Typical example

1. Use the following procedure in order to find thetop dead center position of the appropriate piston.

a. Install 21825666 Valve Spring Compressor(1) and the appropriate 27610235 Adapter(2) in position on the cylinder head in order tocompress the appropriate valve spring (5).

b. Compress the valve spring (5) sufficiently inorder to open the valve only. Do not compressthe valve spring so that the valve keepers (3)could be removed from the recess in the valvestem or so that the valve stem seal (not shown)could be damaged.

c. Slowly turn the crankshaft until the pistontouches the valve.

d. Continue to turn the crankshaft and release thepressure on the valve spring compressor (1)until the piston is at the top center position.

NOTICEEnsure that the valve spring is compressed squarelyor damage to the valve stem may occur.

Note: If you are replacing all of the valve springs,on four cylinder engines only, the procedure canbe done on two cylinders at the same time. Theprocedure can be done on cylinder 1 and cylinder 4,or on cylinder 2 and cylinder 3. Remember that thecrankshaft must not be turned while the valve springsare removed. Ensure that all of the valve springs areinstalled before changing from one pair of cylindersto the other pair of cylinders.



NOTICEDo not turn the crankshaft while the valve springs areremoved.

2. Use the valve spring compressor (1) and theadapter (2) in order to compress the valve spring(5). Remove the valve keepers (3).

3. Remove the valve spring retainer (4) and removethe valve spring (5).

Installation ProcedureTable 2

Required Tools



27610235 Adapter 1



Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

NOTICEInstall suitable plugs to the inlet ports of the cylinderhead in order to prevent the entry of loose parts intothe engine.


1. Place the new valve springs (5) into position onthe cylinder head.

2. Install the valve spring retainer (4).

3. Install the valve spring compressor (1) and theadapter (2) in position on the cylinder head inorder to compress the appropriate valve spring(5). Compress the valve spring (5).


4. Install two valve keepers (3) in order to lock thevalve springs in position.

NOTICEDo not turn the crankshaft while the valve springs areremoved.

5. Carefully release the pressure on the valvespring compressor (1). Remove the valve springcompressor. Ensure that all of the valves aresecured in place by a valve spring and valvekeepers. Rotate the crankshaft through about45 degrees in order to clear the piston from thevalve. Lightly strike the top of the valve with a softhammer in order to ensure that the valve keepers(3) are properly installed.

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



End By:

a. Install the rocker shaft assembly. Refer toDisassembly and Assembly, “Rocker Shaft andPushrod - Install”.

i02187989

Inlet and Exhaust Valves -Remove and Install


Required Tools



27610235 Adapter 1

Start By:

a. Remove the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head - Remove”.



Note: The removal procedure is identical for thetwo cylinder, the three cylinder and the four cylinderengines. The illustrations show the four cylinderengine.

1. Clean the bottom face of the cylinder head.Check the depth of the valves below the face ofthe cylinder head before the valve springs areremoved. Refer to Specifications, “Cylinder HeadValves” for the correct dimensions.

2. Place an identification mark on the heads of thevalves for installation purposes.

Note: The head of the inlet valve has a largerdiameter than the head of the exhaust valve.

3. Position the cylinder head on a suitable surfacewith the valve springs facing upward.

Note: Ensure that the machined face of the cylinderhead is kept on a clean, soft surface in order toprevent damage to the machined surface.





4. Install the 21825666 Valve Spring Compressor(1) and the 27610235 Adapter (2) in positionon the cylinder head in order to compress theappropriate valve spring (5).


5. Apply pressure to the valve spring compressor (1).Remove the valve keepers (3).

6. Slowly release the pressure on the valve springcompressor (1).




Typical example

7. Remove the valve spring retainer (4).

8. Remove the valve spring (5).

9. Repeat steps 4 to 8 for the remaining valves.

10.Remove the valve spring compressor (1) and theadapter (2).

11.Remove the valve stem seals (6).

12.Carefully turn over the cylinder head.

13.Remove the valves (7).


Required Tools



27610235 Adapter 1



Note: The installation procedure is identical for thetwo cylinder, the three cylinder and the four cylinderengines. The illustrations show the four cylinderengine.

1. Clean all parts. Ensure that all ports, all coolantpassages and all lubrication passages are freefrom debris. To inspect the cylinder head, referto Testing and Adjusting, “Cylinder Head Inspect”for further information.

2. Inspect all of the valve seats for wear and fordamage. Refer to Specifications, “Cylinder HeadValves” and refer to Testing and Adjusting, “ValveDepth - Inspect ” for further information.

3. Inspect all of the valve guides for wear and fordamage. Refer to Specifications, “Cylinder HeadValves” and refer to Testing and Adjusting , “ValveGuide - Inspect” for further information.


4. Lubricate the stems of all valves (7) with cleanengine oil. Install the valves (7) in the appropriatepositions.

5. Carefully turn over the cylinder head and ensurethat all of the valves remain in place.

6. Use a suitable tool to install the new valve stemseals (6) onto each of the valve guides.

Note: The outer face of the valve guides must beclean and dry before installing the valve stem seals(6). The inlet valve stem and the exhaust valve stemuse seals that are different parts.

7. Inspect the valve springs (5) for wear and for thecorrect installed length. Refer to Specifications,“Cylinder Head Valves ” for further information.

8. Install the valve spring (5) onto the cylinder head.



9. Install the valve spring retainer (4).





Typical example


10. Install the 21825666 Valve Spring Compressor(1) and the 27610235 adapter (2) in positionon the cylinder head in order to compress theappropriate valve spring (5).


11.Apply pressure to the valve spring compressor(1). Install the valve keepers (3).

The valve keepers can be thrown from the valvewhen the valve spring compressor is released. En-sure that the valve keepers are properly installedon the valve stem. To help prevent personal injury,keep away from the front of the valve keepers andvalve springs during the installation of the valves.

12.Carefully release the pressure on the valve springcompressor (1).

13.Repeat steps 8 to 12 for all of the valves.

14.Remove the valve spring compressor (1) and theadapter (2) from the cylinder head.

15.Place the cylinder head on a suitable support.Ensure that the heads of the valves are notobstructed. Gently strike the top of the valves witha soft hammer in order to ensure that the valvekeepers (3) are properly installed.

16. Turn over the cylinder head and check the depthof the valves below the face of the cylinder head.Refer to Specifications, “Cylinder Head Valves” formore information.

End By:

a. Install the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head - Install”.

i02801641

Engine Oil Line - Remove andInstall

Removal Procedure


1. Loosen the nut (2) that attaches the oil line (1) tothe fuel injection pump.



2. Remove the banjo bolt (3) and remove thewashers (4) from the cylinder block. Discard thewashers (4).


3. Remove the banjo bolt (3) and remove thewashers (4) from the cylinder head. Discard thewashers (4).

4. Remove the oil line (1) from the engine.



Typical example

1. Position the oil line (1) on the engine.

2. Position the banjo bolt (3) and the new washers(4) on the oil line (1). Install the oil line to thecylinder block.


Typical example



3. Position the banjo bolt (3) and the new washers(4) to the oil line (1). Install the oil line to thecylinder head.

4. Install the nut (2) that attaches the oil line (1) tothe fuel injection pump.

For the 402C-05, 403C-07, 403C-11 and 404C-15engines, tighten the nut (2) to a torque of 6 N·m(4.4 lb ft).

For the 403C-15, 403C-17, 404C-22 and404C-22T engines, tighten the nut (2) to a torqueof 15 N·m (11 lb ft).

5. Tighten the banjo bolts (3) to 11.5 N·m (8.5 lb ft).

i02186236

Engine Oil Cooler - Removeand Install

Removal Procedure





1. Drain the coolant from the cooling system intoa suitable container. Drain the engine oil into asuitable container. Refer to the Operation andMaintenance Manual for the procedure on drainingthe coolant and the engine oil.


2. By using a suitable strap wrench, remove theoil filter element (5) from the oil cooler body (3).Discard the oil filter element in a suitable manner.

3. Remove the hose clamps (2) and the hoses (1)from the coolant inlet and the coolant outlet onthe oil cooler body (3). Note the positions of thecoolant inlet and the coolant outlet for installation.

4. Remove the adapter (4) from the oil cooler body(3). Remove the oil cooler body (3) from thecylinder block (7).

5. Remove the O-ring (6) from the oil cooler body(3). Discard the O-ring.




1. Clean the mating surfaces of the oil cooler baseon the cylinder block (7) and clean the oil coolerbody (3).

2. Install a new O-ring (6) to the oil cooler body (3).Install the oil cooler body (3) to the cylinder block(7).

3. Install the adapter (4) through the oil cooler body(3) to the cylinder block (7). Tighten the adapter(4) to a torque of 34 N·m (25 lb ft).



4. Install the appropriate hoses (1) to the coolantinlet and the coolant outlet on the oil cooler body(3). Tighten the hose clamps (2).

5. Lubricate the O-ring of the oil filter element (5) withclean engine oil. Install the new oil filter element tothe oil cooler body (4). Tighten the oil filter elementby hand. Do not use a strap wrench to tighten theoil filter element.

6. Fill the cooling system with coolant. Fill thelubrication system with engine oil. Refer to theOperation and Maintenance Manual, “RefillCapacities” for the cooling system capacity andfor the lubrication system capacity of the engine.

i02182334

Engine Oil Relief Valve -Remove and Install

Removal Procedure






1. Remove the engine oil relief valve (2) from thecylinder block.

2. Remove the O-ring (1) from the engine oil reliefvalve. Discard the O-ring.





1. Install a new O-ring (1) on the engine oil reliefvalve (2).

2. Lubricate the engine oil relief valve (2) with cleanengine oil.

3. Install the engine oil relief valve (2) in the cylinderblock. Tighten the engine oil relief valve to atorque of 64 N·m (47 lb ft).

i02182152

Engine Oil Pump - Remove


a. Remove the front housing. Refer to Disassemblyand Assembly, “Housing (Front) - Remove”.





NOTICEIf the front housing is not installed, do not turn thecrankshaft. Damage to the engine may occur.



Engine Oil Pump


Typical example




1. Remove the C-clip (9) that retains the idler gear(3) on the idler hub (1).

2. Remove the following items from the idler hub (1):

• Collar (8)

• Spring (7)

• Shim (6)

• Oil pump cover (5)

• Inner rotor (4)

3. Remove the idler gear (3) from the idler hub (1).

4. Remove the thrust washer (2) from the idler hub(1).

5. Inspect all the components for wear or damage.Any components that are worn or damaged shouldbe replaced with new parts.

Note: Refer to Specifications, “Engine Oil Pump” formore information.

6. If the engine oil pump has excessive buildup ofsludge, inspect the oil strainer. The oil strainer canbe removed by using the following procedure:

a. Remove the engine oil pan. Refer toDisassembly and Assembly, “Engine Oil Pan -Remove and Install”.


b. Remove the setscrews (12) and the oil strainer(13) from the cylinder block. Inspect theoil strainer for damage. If the oil strainer isdamaged, use a new part for replacement.

c. Remove the oil tube (11) from the cylinderblock.

d. Remove the O-ring (10) from the oil tube.Discard the used O-ring.



Idler Hub


1. Remove the crankshaft. Refer to Disassembly andAssembly, “Crankshaft - Remove”.

2. Use a hammer and use a suitable drift to removeidler hub (1) from the cylinder block (2). Align thedrift to the rear face of the hub and drive the hubfrom the inside of the cylinder block outward.

i02801642

Engine Oil Pump - Install


Required Tools

ToolPart

Number Part Description Qty

A(1) 21825624 Alignment Tool 1



B - Multipurpose Grease 1(1) 402C-05 and 403C-07 engines(2) 403C-11 and 404C-15 engines(3) 403C-15, 403C-17, 404C-22 and 404C-22T engines



NOTICEIf the front housing is not installed, do not turn thecrankshaft. Damage to the engine may occur.

Idler Hub


1. Install the pin of Tooling (A) to the cylinder block.

2. Position the guide plate of Tooling (A) onto idlerhub (1). Align the guide plate of Tooling (A) withpin of Tooling (A).

3. Use a hammer in order to strike the guide plate ofTooling (A). This will install idler hub (1).

4. Remove Tooling (A).



Engine Oil Pump



Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

1. Apply Tooling (B) to the faces of inner rotor (4)and to the vanes of idler gear (3).

2. Align timing marks (X) on idler gear (3) with therespective timing marks on gears (14) and (15).Install idler gear (3) onto idler hub (1).

3. Install inner rotor (4) to idler gear (3).

Personal injury can result from the release of thespring force.

The drive shaft, the piston, and the drive gear areunder spring force.

Use a press to slowly release the spring force be-fore the components are removed.

4. Install the following items to idler hub (1):

• Oil pump cover (5)

• Shim (6)

• Spring (7)

• Collar (8)

Refer to Illustration 40.

5. Install retaining ring (9) on idler hub (1).


Checking end play by using a feeler gauge

6. Use a feeler gauge in order to measure the endplay of engine oil pump. Refer to Specifications,“Engine Oil Pump”.

7. If the oil strainer was removed, use the followingprocedure for installation:




a. Install a new O-ring seal (10) on oil tubeassembly (11).

b. Install oil tube assembly (11) in the cylinderblock.

c. Install oil strainer (13) to the cylinder block andtighten bolts (12) to a torque of 11 N·m (8 lb ft).

End By:

a. Install the front housing. Refer to Disassembly andAssembly, “Housing (Front) - Install”.

b. Install the engine oil pan. Refer to Disassemblyand Assembly, “Engine Oil Pan - Remove andInstall”.

i02801654

Water Pump - Remove

Removal Procedure (403C-11,403C-15, 403C-17, 404C-15,404C-22 and 404C-22T Engines)Start By:

a. Remove the fan. Refer to Disassembly andAssembly, “Fan - Remove and Install”.

b. Remove the alternator. Refer to Disassembly andAssembly, “Alternator - Remove and Install”.





1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “RefillCapacities” for the approximate capacity of thecooling system.

2. Loosen the clamps and remove the hose from thewater pump inlet (not shown).


3. Remove the fasteners (2) and the alternatorbracket (1) from the water pump (3).




Typical example

4. Loosen the clamps (2) and remove the bypasshose (3) from the water pump (6).

5. Remove the setscrews, the washers (4) and thenut (5).

6. If necessary, gently tap the water pump (6) with asoft faced hammer in order to loosen the waterpump (6).

7. Remove the water pump (6). Remove the joint (1)from the cylinder block. Discard the joint (1).

Removal Procedure (402C-05 and403C-07 Engines)Start By:

a. Remove the fan. Refer to Disassembly andAssembly, “Fan - Remove and Install”.

b. Remove the alternator. Refer to Disassembly andAssembly, “Alternator - Remove and Install”.






2. Loosen the clamps and remove the hose from thewater pump inlet (not shown).

g01124100Illustration 46typical example

3. Remove the fasteners (2) and the alternatorbracket (1) from the water pump (3).




Typical example

4. Loosen the clamps (3) and remove the bypasshose (4) from the water pump (7).

5. Remove the setscrews, the washers (5) and thenut (6).

6. If necessary, gently tap the water pump (7) with asoft faced hammer in order to loosen the waterpump (7).

7. Remove the water pump (7). Remove the joint (8),the spacer (1), and the joint (2) from the cylinderhead. Discard the joint (8) and the joint (2).

i02801657

Water Pump - Install

Installation Procedure (403C-11,403C-15, 403C-17, 404C-15, 404C-22and 404C-22T Engines)



1. Remove all debris and gasket material fromthe mating surfaces of the water pump and thecylinder block.


Typical example

2. Install a new gasket (1) in position on the engine.

3. Place the water pump (6) in position on the engineand install the setscrews, the washers (4) and thenut (5). Tighten setscrews, the washers (4) andthe nut (5) to a torque of 10 N·m (7.4 lb ft).


4. Place the alternator bracket (1) into position onwater pump (6). Install the fasteners (2) on thewater pump (6) and hand tighten the fasteners (2).

5. Install the lower hose and install the hose clamp(not shown). Hand tighten the hose clamp. Installthe hose (3) on the water pump (6) and tighten thehose clamps (2) to a torque of 2.5 N·m (22.1 lb in).



End By:

a. Fill the cooling system with coolant to the correctlevel. Refer to Operation and MaintenanceManual, “Refill Capacities”.

b. Install the pulley, the adapter and the fan. Refer toDisassembly and Assembly, “Fan - Remove andInstall”.

c. Install the V-Belts. Refer to Disassembly andAssembly, “V-Belts - Remove and Install”.

Installation Procedure (402C-05and 403C-07 Engines)



1. Remove all debris and gasket material fromthe mating surfaces of the water pump and thecylinder block.


Typical example

2. Install new gaskets (8) and (2) and the spacer (1)in position on the engine.

3. Place the water pump (7) in position on the engineand install the setscrews, the washers (5) and thenut (6). Tighten setscrews, the washers (5) andthe nut (6) to a torque of 10 N·m (7.4 lb ft).


4. Place the alternator bracket (1) into position onwater pump (7). Install the fasteners (2) on thewater pump (7) and hand tighten the fasteners (2).

5. Install the lower hose and install the hose clamp(not shown). Hand tighten the hose clamp. Installthe hose (4) on the water pump (7) and tighten thehose clamps (3) to a torque of 2.5 N·m (22.1 lb in).

End By:

a. Fill the cooling system with coolant to the correctlevel. Refer to Operation and MaintenanceManual, “Refill Capacities”.

b. Install the pulley, the adapter and the fan. Refer toDisassembly and Assembly, “Fan - Remove andInstall”.

c. Install the V-Belts. Refer to Disassembly andAssembly, “V-Belts - Remove and Install”.

i02182980

Water Temperature RegulatorHousing - Remove and Install

Removal Procedure







1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto the OEM for the approximate capacity ofthe cooling system. Refer to the Operation andMaintenance Manual, “Cooling System Coolant(DEAC) - Change” or Operation and MaintenanceManual, “Cooling System Extended Life Coolant- Change”.


2. Remove the setscrews (4) and the nuts (3).

3. Remove the water temperature regulator housing(2) from the cylinder head.

4. Remove the gasket (1) from the cylinder head.Discard the gasket.




1. Clean the mating surfaces of the cylinderhead. Clean the mating surfaces of the watertemperature regulator housing.


2. Install a new gasket (1) on the cylinder head.

3. Install the water temperature regulator housing(2) to the cylinder head.

4. Install the setscrews (4) and the nuts (3) thatfasten the water temperature regulator housingto the cylinder head. Tighten the fasteners to atorque of 10 N·m (7.4 lb ft).

5. Fill the cooling system with coolant to the correctlevel. Refer to the Operation and MaintenanceManual, “Refill Capacities” for more information.

i02801658

Water Temperature Regulator -Remove and Install

Removal Procedure (402C-05 and403C-07 engines)









Personal injury can result from parts and/or cov-ers under spring pressure.

Spring force will be released when covers are re-moved.

Be prepared to hold spring loaded covers as thebolts are loosened.

2. Remove the setscrews (6) and the nuts (5).

3. Remove the outlet connection (4) for the watertemperature regulator.

4. Remove the joint (3).

5. Remove the water temperature regulator (2) andthe spring (1) from the cylinder head.

6. Inspect the water temperature regulator (2)for wear or damage. If the water temperatureregulator is worn or damaged, use a new partfor replacement. Refer to Testing and Adjusting,“Water Temperature Regulator - Test” for moreinformation on testing the water temperatureregulator.

Removal Procedure (403C-11,403C-15, 403C-17, 404C-15,404C-22 and 404C-22T engines)







Typical example

2. Remove the setscrews (1).



3. Remove the outlet connection (2) for the watertemperature regulator.

Note: Identify the orientation of the outlet connectionfor installation.

4. Remove the joint (3).

5. Remove the water temperature regulator (4) fromthe water temperature regulator housing (5).

6. Inspect the water temperature regulator (4)for wear or damage. If the water temperatureregulator is worn or damaged, use a new partfor replacement. Refer to Testing and Adjusting,“Water Temperature Regulator - Test” for moreinformation on testing the water temperatureregulator.

Installation Procedure (402C-05and 403C-07 engines)



1. Remove all debris and gasket material from themating surfaces of both the outlet connection(4) for the water temperature regulator and thecylinder head.





2. Install the spring (1) and the water temperatureregulator (2) to the cylinder head.

Note: Install the water temperature regulator with thejiggle pin in the vertically upward position.

3. Install a new joint (3) to the cylinder head.

4. Install the outlet connection (4) to the cylinderhead.

5. Install the nut (5) and the setscrews (6) to theoutlet connection (4).

6. Tighten the fasteners to a torque of 6 N·m(53 lb in).

7. Fill the cooling system with coolant to the correctlevel. Refer to Operation and MaintenanceManual, “Refill Capacities” for more information.

Installation Procedure (403C-11,403C-15, 403C-17, 404C-15, 404C-22and 404C-22T engines)



1. Remove all debris and all gasket material from themating surfaces of both the outlet connection (2)and the water temperature regulator housing (5).




2. Install the water temperature regulator (4) to thewater temperature regulator housing (5). Referto specifications, “Water Regulator Housingfor 403C-11, 403C-15, 403C-17, 404C-15,404C-22and 404C-22T Engines” for the correctorientation of the water temperature regulator.

3. Install a new joint (3) to the cylinder head.

4. Install the outlet connection (2) to the watertemperature regulator housing (5).

Note: Ensure the correct orientation of the outletconnection.

5. Install the setscrews (1) to the outlet connection(2).

6. Tighten the setscrews to a torque of 14 N·m(10 lb ft).

7. Fill the cooling system with coolant to the correctlevel. Refer to Operation and MaintenanceManual, “Refill Capacities” for more information.

i02183594

Flywheel - Remove


a. Remove the electric starting motor. Refer toDisassembly and Assembly, “Electric StartingMotor - Remove and Install”.



Note: The two cylinder, the three cylinder and thefour cylinder engines have different flywheels. Theremoval procedure is similar for all models.


Typical example

1. Install a suitable lifting device (1) to the flywheel(2).

2. Remove two setscrews (3) opposite each otherfrom the flywheel.

3. Install two suitable guide studs in the place of thesetscrews that were removed.

4. Remove the remaining setscrews (3) that fastenthe flywheel to the crankshaft.

5. Remove the flywheel (2) from the rear of thecrankshaft.

Note: On some three cylinder engines, a roll pin islocated between the crankshaft and the flywheel.

6. Inspect the flywheel ring gear (5) and the flywheel(2) for wear or damage. If the flywheel ring gear orthe flywheel is worn or damaged, use new partsfor replacement.




Typical example

7. To remove the flywheel ring gear (5) from theflywheel (2), place the flywheel on a suitablesupport. Use a suitable hammer (not shown) anda punch (4) in order to remove the ring gear fromthe flywheel.

i02183590

Flywheel - Install




Always wear protective gloves when handlingparts that have been heated.


1. Thoroughly clean the flywheel housing. Inspectthe crankshaft rear seal for leaks. If there areany oil leaks refer to Disassembly and Assembly,“Crankshaft Rear Seal - Remove”.

2. If necessary, perform the following procedure toinstall the ring gear (2) to the flywheel (1).

a. Identify the orientation of the new ring gear inorder to install the ring gear correctly onto theflywheel.

Note: The chamfered side of the gear teeth (3) mustface toward the starting motor when the flywheel isinstalled. This will ensure the correct engagement ofthe starting motor.

b. Heat the flywheel ring gear (2) in an oven to amaximum temperature of 150°C (302°F) priorto installation.

Note: Do not use a torch to heat the ring gear.

c. Ensure that the orientation of the ring gear (2)is correct and quickly install the ring gear ontothe flywheel (1).




3. Install a suitable lifting device (4) to the flywheel(1).

4. Install two suitable guide studs opposite eachother in the end of the crankshaft.

5. Position the flywheel (1) onto the two guide studs.

On three cylinder engines that have a roll pin,ensure that the roll pin is installed to the crankshaftand that the roll pin is free from damage. Alignthe hole in the flywheel with the roll pin in thecrankshaft.

6. Install the setscrews (5) that fasten the flywheelto the crankshaft.

7. Remove the two guide studs and install the tworemaining setscrews (5) in the flywheel.

8. Use a suitable tool to prevent the flywheel (1) fromrotating. Tighten the setscrews (5) to a torque of73.5 N·m (54.2 lb ft).

9. Remove the lifting device (4) from the flywheel.

Note: Refer to Specifications, “Flywheel” forinformation on flywheel runout.

End By:

a. Install the electric starting motor. Refer toDisassembly and Assembly, “Electric StartingMotor - Remove and Install”.

i02183600

Crankshaft Rear Seal - Remove


a. Remove the flywheel housing. Refer toDisassembly and Assembly, “Flywheel Housing- Remove and Install”.





Note: The two cylinder, the three cylinder and thefour cylinder engines have different configurations forthe flywheel housing and the backplate. The removalprocess is similar for all models.


Typical example

1. Remove the setscrews (3) and the backplate (2)from the rear of the cylinder block.

2. Remove the crankshaft rear seal (1) from thecylinder block. Discard the used crankshaft oilseal.

i02801659

Crankshaft Rear Seal - Install

Installation ProcedureNote: Inspect the crankshaft rear seal and replacethe assembly if there is the slightest sign of damageto the seal.

Note: The following procedure assumes that thecrankshaft rear seal is a replacement assembly.






1. Clean the rear face of the cylinder block (1) andthe back plate (6). Inspect the dowels (3) fordamage. If the dowels are damaged, use newparts for replacement.

2. Ensure that the crankshaft flange (4) is clean, dryand free from rough metal edges.

3. Remove the packaging from the new crankshaftrear seal (5). Ensure that the plastic sleeve (notshown) is squarely installed within the crankshaftrear seal. The plastic sleeve is included in orderto protect the lip of the seal as the lip is pushedover the crankshaft flange.

4. Apply clean engine lubricating oil to the crankshaftflange (4) around the running surface of crankshaftrear seal.

5. Place the crankshaft rear seal (5) over thecrankshaft flange (4) and engage the plasticsleeve onto the crankshaft flange.

6. Ensure that the plastic sleeve is engaged ontothe crankshaft flange (4). Push the crankshaftrear seal (5) evenly and push the crankshaft rearseal smoothly onto the crankshaft flange until thecrankshaft rear seal is against the cylinder block.During this process, the plastic sleeve will beforced out of the crankshaft rear seal. Discard theplastic sleeve.



7. Apply a continuous bead of 21826038POWERPART Silicone Adhesive to the rear faceof the cylinder block around the mating surface ofthe crankshaft rear seal and around the rear coreplug for the camshaft (2).

8. Align the back plate (6) to the dowels (3) andinstall the back plate to the cylinder block (1).

9. Install the setscrews (7) that fasten back plate (6)to the cylinder block (1).

For the 402C-05 and 403C-07 engines, tightenthe setscrews to a torque of 15 N·m (11 lb ft).

For the 403C-11 and 404C-15 engines, tighten thesetscrews to a torque of 50 N·m (37 lb ft).

For the 403C-15, 403C-17, 404C-22 and404C-22T engines, tighten the setscrews to atorque of 25 N·m (19 lb ft).

End By:

a. Install the flywheel housing. Refer to Disassemblyand Assembly Manual, “Flywheel Housing -Remove and Install”.

b. Install the flywheel. Refer to Disassembly andAssembly Manual, “Flywheel - Install”.

i02801660

Flywheel Housing - Removeand Install

Removal Procedure (Engines withFlywheel Housing and Back plate)Start By:

a. Remove the flywheel. Refer to Disassembly andAssembly, “Flywheel - Remove”.



1. Support the engine with a suitable lifting device orsupport the engine on blocks that are positionedon a flat level surface.

2. Install a suitable lifting device (9) to the flywheelhousing and support the weight of the housing (8).


3. Remove the setscrews (3) that fasten the flywheelhousing (8) to the cylinder block.

4. Remove the setscrews (5) on each side ofthe cylinder block. These setscrews fasten theflywheel housing (8) to the cylinder block.

5. Remove the setscrews (1) that fasten the backplate (2) to the flywheel housing (8).

6. Remove the nuts (7) and the bolts (not shown)that fasten the back plate (2) to the flywheelhousing (8).


Typical example

7. Use the lifting device (9) to remove the flywheelhousing (8) from the back plate.



Removal Procedure (Engines withFlywheel Housing)Start By:

a. Remove the flywheel. Refer to Disassembly andAssembly, “Flywheel - Remove”.



Note: The two cylinder, the three cylinder and the fourcylinder engines have different flywheel housings.The removal procedure is similar for all models.

1. Support the engine with a suitable lifting device orsupport the engine on blocks that are positionedon a flat level surface.

2. Install a suitable lifting device (3) to the flywheelhousing and support the weight of the housing (2).


3. Remove the setscrews (1) that fasten the flywheelhousing (2) to the cylinder block.


Typical example

4. Use the lifting device (3) to remove the flywheelhousing (2) from the engine.

Installation Procedure (Engineswith Flywheel Housing and Backplate)






1. Clean the rear face of the back plate (2) and thefaces of the flywheel housing (8). Inspect thecrankshaft rear seal (not shown) for leaks. Inspectthe dowels (6) for damage. If the crankshaftrear seal or the dowels are damaged, use newparts for replacement. Refer to Disassembly andAssembly, “Crankshaft Rear Seal - Remove” andDisassembly and Assembly, “Crankshaft RearSeal - Install”.


Typical example

2. Use the lifting device (9) to align the flywheelhousing (8) to the dowels (6). Install the flywheelhousing to the back plate.

3. Install the nuts (7) and the bolts (not shown) thatfasten the back plate (2) to the flywheel housing(8).

4. Install the setscrews (1) that fasten the back plate(2) to the flywheel housing (8).

5. Install the setscrews (5) on each side of thecylinder block. These setscrews fasten theflywheel housing (8) to the cylinder block.

6. Remove the lifting device (9) from the flywheelhousing.

7. Install the setscrews (3) that fasten the flywheelhousing (8) to the cylinder block.

8. For 403C-15, 404C-22 and 404C-22T engines,tighten the fasteners to a torque of 25 N·m(19 lb ft).

End By:

a. Install the flywheel. Refer to Disassembly andAssembly, “Flywheel - Install”.

Installation Procedure (Engineswith Flywheel Housing)




Typical example

1. Clean the mating face of the flywheel housing(2). Inspect the crankshaft rear seal (4) forleaks. Inspect the dowels (5) for damage. Ifthe crankshaft rear seal or the dowels aredamaged, use new parts for replacement. Referto Disassembly and Assembly, “Crankshaft RearSeal - Remove” and Disassembly and Assembly,“Crankshaft Rear Seal - Install”.


2. Use the lifting device (3) to align the flywheelhousing (2) to the dowels (5). Install the flywheelhousing to the engine.



3. Install the setscrews (1) that fasten the flywheelhousing to the cylinder block.

For 402C-05 and 403C-07 engines, tighten thesetscrews to a torque of 15 N·m (11 lb ft).



4. Remove the lifting device (3) from the flywheelhousing.

End By:

a. Install the flywheel. Refer to Disassembly andAssembly, “Flywheel - Install”.

i02801663

Crankshaft Pulley - Removeand Install


Required Tools

Part Number Description Qty

21825619 Puller 1

1. Remove the fan drive belt. Refer to Disassemblyand Assembly, “V Belts Remove and Install” formore information.


1. Remove the nut (5) and the washer (3) fromcrankshaft pulley (2).


2. Install the 21825619 Puller (6) to the crankshaftpulley. Use the puller (6) in order to remove thecrankshaft pulley (2) from crankshaft (4).

3. Remove the woodruff key (1) from the crankshaft(4).



Note: Inspect the following components for damage:the taper of the crankshaft, the woodruff key, andthe bore of the crankshaft pulley. Replace anycomponents that are damaged. Ensure that the taperof the crankshaft and the bore of the crankshaftpulley are clean and dry before assembly.

1. Install the woodruff key (1) to the crankshaft (4).

2. Install the crankshaft pulley (2) to the crankshaft(4).

3. Install the washer (3) to the crankshaft (4).

4. Lubricate the nut (5) with clean engine oil andinstall the nut.

For 402C-05 and 403C-07 engines, tighten thenut (5) to a torque of 93 N·m (69 lb ft).



For 403C-11 and 404C-15 engines, tighten the nut(5) to a torque of 123 N·m (91 lb ft).

For 403C-15, 403C-17, 404C-22 and 404C-22Tengines, tighten the nut (5) to a torque of 304 N·m(224 lb ft).

5. Install the V-belt to the engine. Refer toDisassembly and Assembly, “V Belts Remove andInstall” for more information.

i02200446

Crankshaft Front Seal -Remove

Removal Procedure



NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.


Remove the Front Oil Seal that is installedin the Engine

1. If the front cover is still attached to the engine, usea suitable lever in order to remove the oil sealfrom the front cover.

Remove the Front Oil Seal from aDisassembled Front Cover

1. If the front cover has been removed from theengine, use a suitable hydraulic press in order toremove the oil seal from the front cover. Ensurethat the front cover is supported correctly in orderto prevent damage to the cover while the oil sealis being removed.

i02187983

Crankshaft Front Seal - Install





1. Clean the bore of the housing (1) for the crankshaftfront seal (2) and inspect the bore of the housingfor any damage.

2. Lubricate the crankshaft front seal (2) with cleanengine oil.

3. Position the crankshaft front seal (2) in the bore ofthe housing (1) for the crankshaft front seal.

NOTICEEnsure that the lip of the crankshaft front seal that isspring loaded is facing toward the inside of the fronthousing and that it is square with the bore of the hous-ing for the crankshaft front seal.

4. Use a suitable tool (3) to install the new crankshaftfront seal (2).

Note: Apply clean engine oil on the area of thecrankshaft pulley that will be in contact with thecrankshaft front seal (2).

End By:

a. Install the crankshaft pulley and the V-belt. Referto Disassembly and Assembly, “Crankshaft Pulley- Remove and Install”.



i02186336

Housing (Front) - Remove


a. Remove the fuel injection pump. Refer toDisassembly and Assembly, “Fuel Injection Pump- Remove”.

b. Remove the crankshaft pulley. Refer toDisassembly and Assembly, “Crankshaft Pulley- Remove and Install”.






Typical example

1. Remove the setscrews and the nuts (5) from thefront housing (4).

2. Turn the mechanical stop lever (3) to the fullclockwise position so that the spring is held undertension.

3. Remove the front housing (4) from the front ofcylinder block (6).

Note: Identify the position of the locating pin (2) andthe locating hole (1) for installation.

4. Remove the joint (not shown) from the cylinderblock (6) or from the front housing (4). Discard thejoint.

5. Inspect the front housing assembly (4) for wearor damage. If the front housing assembly isdamaged, use new parts for replacement.



i02186302

Housing (Front) - Disassemble

Disassembly ProcedureStart By:

a. Remove the engine front housing. Refer toDisassembly and Assembly, “Housing (Front) -Remove”.





Removal of the Throttle Control


Typical example

1. Remove the spring (5) from the lever (8) for thethrottle control.

2. Loosen the nut (1) and the bolt (4) that securesthe arm (3) to the lever (8) for the throttle control.

Note: Identify the position of the arm in relation to thelever for installation. Do not remove the nut (1) andthe washers (2) from the bolt (4).

3. Remove the arm (3) from the lever (8).

4. Remove the C-clip (6) from the lever (8).

5. Remove the lever (8) from the front housing (9).

6. Remove the O-ring (7) from lever (8). Discard theO-ring.

7. Check the components for wear or damage.Replace any components that are worn ordamaged.

Removal of the linkage for the FuelInjection Pump

Note:When the linkage for the fuel injection pump isremoved or the engine front cover is replaced, thesetting for the maximum fuel may be affected.




Typical example

1. Remove the spring (10) from the lever assembly(11).

2. Remove the C-clip (14) from the shaft (12).

3. Remove the shaft (12) and remove the leverassembly (11) from the engine front housing (9).

4. Remove the O-ring (13) from the shaft (12).Discard the O-ring.

5. Remove the angleich unit (15) from the leverassembly (11).

Note: The angleich unit is not installed to the402C-05, 403C-07, 403C-11 and 404C-15 engines,or engines that run at a constant speed.

6. Check the components for wear or damage.Replace any components that are worn ordamaged.

Removal of the Stop Control


1. Remove the nut (16) and remove the washer (17)that secures the lever (18) to the arm (24) for thestop control.

2. Remove the lever (18) from the arm (24) for thestop control.

Note: Identify the position of the lever (18) on theshaft (24) for installation.

3. Remove the nut (19) from the arm (24) for thestop control. Remove the washer (20) and removethe spring (21) from the arm (24).

4. Remove the arm (24) for the stop control from thefront housing.

5. Remove the C-clip (23) and the O-ring (22) fromthe arm (24). Discard the O-ring.



Removal of the PTO Cover


1. Remove the nuts (25) and the bolts (31) from thePTO cover.

2. Remove the plates (26) and (30).

Note: The plate (30) is not installed on 402C-05 or403C-07 engines.

3. Remove the joint (27) and discard the joint.

4. Remove the O-ring (29). Discard the O-ring.

Note: The O-ring (29) is not installed on 402C-05or 403C-07 engines.

5. Check the condition of all parts. Replace any partsthat are damaged or worn.

i02801664

Housing (Front) - Assemble

Assembly ProcedureNote: If the engine front housing is replaced, ensurethat a new emissions label is installed.

Installation of the Throttle Control


Typical example

1. Install the O-ring (6) to the shaft of the lever (7).

2. Lubricate the O-ring (6) and the shaft of the lever(7) with clean engine oil. Install the lever (7) intothe front housing (8).

3. Install the C-clip (5) onto the shaft of the lever (7).

4. Install the arm for the throttle control (3) onto thelever (7). Tighten the nut (1) and bolt (4) to atorque of 9 N·m (7 lb ft).

Installation of the linkage for the FuelInjection Pump

1. If necessary, perform the following procedure toinstall the angleich unit (15) to the lever assembly(11).




a. Apply 21820117 POWERPART Threadlock tothe first two threads of the angleich unit (18).

b. Install the angleich unit (18) to the leverassembly (11). Tighten the angleich unit to atorque of 5 N·m (44 lb in).

Note: Ensure that no 21820117 POWERPARTThreadlock is allowed to contaminate the plungerassembly of the angleich unit. Contamination ofthe plunger assembly will render the angleich unitinoperative.


2. Install the spring (10) to the lever assembly (11).

3. Install the O-ring (13) to the shaft (12). Lubricatethe shaft with clean oil.

4. Position the lever assembly (11) in the fronthousing (8). Install the shaft (12) to outside of thefront housing (8).

Note: Ensure that the groove for the C-clip (16) inthe shaft (12) is positioned between the boss (15) onthe front housing and the cast retainer (17) on thefront housing (8).

5. Install the C-clip (14) to the shaft (12).




Typical example

6. Attach the spring (10) to the notch on the insideof the front housing (8).

7. Install the spring (9) to the lever assembly (11).

8. Attach the spring (9) to the lever (7).

Installation of the Stop Control


1. Install the C-clip (26) and install the O-ring (25) tothe arm (27).

2. Lubricate the O-ring (25) and the shaft of the arm(27) with clean oil. Install the arm assembly (27) tothe front housing.

3. Place the spring (24) and the washer (23) onto thearm (27). Install the nut (22) onto the arm (27).

4. Install the lever (21) onto the arm (27).

5. Install the washer (20) and the nut (19) onto thearm (27). Tighten the nuts (19) and (22) to atorque of 10 N·m (7 lb ft).

Installation of the PTO Cover


Note: The O-ring (32) and the plate (33) are notinstalled on the 402C-05 and 403C-07 engines.

1. For 403C-11, 403C-15, 403C-17, 404C-15,404C-22 and 404C-22T engines, install the O-ring(32) to the groove in the front housing (31).

2. Install a new joint (30) to the rear of the fronthousing.

3. For 403C-11, 403C-15, 403C-17, 404C-15,404C-22 and 404C-22T engines, install the plates(29) and (33).

For 402C-05 and 403C-07 engines, install theplate (29).

4. Install the nuts (28) and the bolts (34) for the PTOcover. Tighten the nuts to a torque of 13 N·m(10 lb ft).

End By:

a. Install the front housing to the engine. Refer toDisassembly and Assembly, “Housing (Front)Install” for more information.



b. Check the maximum engine speed at no load.Refer to Testing and Adjusting, “Engine Speed -Check” for more information.

i02801665

Housing (Front) - Install


Required Tools


21825620 Seal Guide402C-05, 403C-07, 403C-11and 404C-15 engines

1

21825621 Seal Guide403C-15, 403C-17, 404C-22and 404C-22T engines

1



1. Clean the front housing assembly (4) thoroughly.

2. For 402C-05, 403C-07, 403C-15 and 404C-11engines, install the 21825620 Seal Guide (6) tothe crankshaft.

For 403C-15, 403C-17, 404C-22 and 404C-22Tengines, install the 21825621 Seal Guide (6) tothe crankshaft.


3. Align the locating pin (2) with the locating hole onthe oil pump cover (1). Ensure that the oil pumpcover is concentric to the idler gear assembly.

4. Install a new joint to the front of the cylinder block(7).

5. Turn the mechanical stop lever (3) to the fullclockwise position so that the spring is held undertension. Observe the position of the linkage forthe fuel injection pump (not shown) in the fronthousing.

6. Position the front housing (4) on the front ofcylinder block (7). Guide the linkage for the fuelinjection pump into position so that the link is freeto move inside the aperture on the cylinder blockfor the fuel injection pump.

7. Align the front housing (4) with the dowels in thefront of the cylinder block (7). Press the fronthousing into position. Release the stop lever (3).

8. Install the fasteners (5) finger tight.

9. Tighten the fasteners (5) to a torque of 10 N·m(7 lb ft).

10.Remove seal guide (6) from the crankshaft.



End By:

a. Install the crankshaft pulley. Refer to Disassemblyand Assembly, “Crankshaft Pulley - Remove andInstall”.

b. Install the fuel injection pump. Refer toDisassembly and Assembly, “Fuel Injection Pump- Install”.

i02187994

Crankcase Breather - Removeand Install

Removal Procedure (NaturallyAspirated Engines)





The two cylinder, the three cylinder and the fourcylinder engines have different crankcase breathers.The removal procedure is identical for all models.


Typical example

1. Remove the setscrews (1) and remove thebreather cover (2) from the valve mechanismcover (10).

2. Remove the spring (3). Remove the diaphragmassembly (4).

3. Clean the vent hole (6). Clean the cavity (5) forthe breather assembly in the valve mechanismcover (10).

4. If necessary, remove the setscrews (7). Removethe plate (8) and remove the gauze (9).

5. Clean all parts and inspect all parts. Replace anyparts that are worn or damaged.

Removal Procedure (TurbochargedEngines)








Typical example

1. Remove the setscrews (1) and remove thebreather cover (2) from the valve mechanismcover (12).

2. Remove the spring (3). Remove the diaphragmassembly (4).

3. Remove the adapter (6). Remove the joint (7).Clean the vent hole (5).

4. Clean the cavity (8) for the breather assembly inthe valve mechanism cover (12).

5. If necessary, remove the setscrews (9). Removethe plate (10) and remove the gauze (11).

6. Clean all parts and inspect all parts. Replace anyparts that are worn or damaged.

Installation Procedure (NaturallyAspirated Engines)



NOTICEMake sure that the components of the breather as-sembly are installed correctly. Engine damage mayoccur if the breather assembly is not working properly.

The two cylinder, the three cylinder and the fourcylinder engines have different crankcase breathers.The installation procedure is identical for all models.


Typical example



1. If necessary, install a new gauze (9). Apply abead of 1861108 POWERPART silicon jointingcompound to the mating face of the plate in thevalve mechanism cover (10). Install the plate (8).Install the setscrews (7). Tighten the setscrews toa torque of 1.5 N·m (13 lb in).

2. Install a new diaphragm assembly (4) into cavity(5) of the valve mechanism cover. Install a newspring (3).

3. Install the breather cover (2) and the foursetscrews (1). Tighten the setscrews to a torqueof 3 N·m (27 lb in).

Installation Procedure(Turbocharged Engines)



NOTICEMake sure that the components of the breather as-sembly are installed correctly. Engine damage mayoccur if the breather assembly is not working properly.


1. If necessary, install a new gauze (11). Apply abead of 1861108 POWERPART silicon jointingcompound to the mating face of the plate in thevalve mechanism cover (12). Install the plate (10).Install the setscrews (9). Tighten the setscrews toa torque of 1.5 N·m (13 lb in).

2. Install a new joint (7). Install the adapter (6).

Note: the connection on the adapter should face tothe rear of the engine. The vent hole (5) should faceupward.

3. Install a new diaphragm assembly (4) into theadapter (6). Install a new spring (3).

4. Install the breather cover (2) and the foursetscrews (1). Tighten the setscrews to a torqueof 3 N·m (27 lb in).



i02801666

Valve Mechanism Cover -Remove and Install

Removal Procedure





Note: The removal procedure is similar for the twocylinder, the three cylinder and the four cylinderengines. The illustrations show the four cylinderengine.

Note: The inlet manifold is part of the valvemechanism cover.


Typical example

1. Remove the setscrews (2) from the connector(3) and remove the connector from the valvemechanism cover (6). Remove the gasket (4).Discard the gasket.

2. Remove the setscrews (1) and remove the capnuts (5) that attach the valve mechanism cover (6)to the housing (7) for the rocker shaft assembly.

3. Remove the valve mechanism cover (6) from thehousing (7) for the rocker shaft assembly. Removethe joint (8) from the valve mechanism cover (6).Inspect the joint. If the joint is worn or damaged,use a new part for replacement.





1. Clean all surfaces thoroughly.


2. Install the joint (8) to the valve mechanism cover(6).

3. Install the valve mechanism cover (6) to thehousing (7) for the rocker shaft assembly.



4. Install the setscrews (1) and install the cap nuts(5).

5. For 402C-05 and 403C-07 engines, tighten thesetscrews and cap nuts to a torque of 10 N·m(7.5 lb ft).

For 403C-11 and 404C-15 engines, tighten thesetscrews and the cap nuts to a torque of 11 N·m(8.1 lb ft).

For 403C-15, 403C-17, 404C-22 and 404C-22Tengines, tighten the setscrews and the cap nutsto a torque of 14 N·m (10 lb ft).

6. Install a new gasket (4) to the valve mechanismcover (6). Install the connector (3) to the valvemechanism cover (6) with setscrews (2). Tightenthe setscrews to a torque of 14 N·m (10 lb ft).

i02187973

Rocker Shaft and Pushrod -Remove


a. Remove the engine oil line. Refer to Disassemblyand Assembly, “Engine Oil Line - Remove andInstall”.

b. Remove the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover - Remove and Install”.





Note: The removal procedure is similar for the twocylinder, the three cylinder and the four cylinderengines. The illustration shows the four cylinderengine.


Typical example

1. Loosen the nuts and the adjustment screws (3)on the rocker arms in order to release the tensionfrom the rocker shaft assembly (4).

2. Remove the nuts (2) and the setscrews (1) fromthe rocker shaft assembly (4).

3. Remove the rocker shaft assembly (4) fromcylinder head (7).

4. Remove the pushrods (6) from the cylinder head.Mark the pushrods for installation. Inspect thepushrods for wear or for damage. If the pushrodsare damaged, use new parts for replacement.

5. Remove the caps (not shown) from the top of thevalve stems (5). Mark the caps for installation.Inspect the caps for wear or for damage. If thecaps are worn or damaged, use new parts forreplacement.

6. Remove the joint (9) from the base of the rockershaft assembly (8). Inspect the joint. If the joint isworn or damaged, use a new part for replacement.



i02801667

Rocker Shaft - Disassemble

Disassembly Procedure (402C-05,403C-07, 403C-11 and 404C-15engines)Start By:

a. Remove the rocker shaft and the pushrods. Referto Disassembly and Assembly, “Rocker Shaft andPushrod - Remove”.




Typical example

1. Remove the threaded plug (6) from the base ofthe rocker shaft (8).

2. Remove the O-ring (5) from the threaded plug (6).Discard the O-ring.

3. On 403C-07, 403C-11 and 404C-15 engines,remove the setscrew (7) that locates the rockershaft (4) to the base of the rocker shaft (8).

4. In order to remove the rocker shaft (4), install asuitable setscrew with a M8 x 1.25 thread into theend of the rocker shaft. Use the setscrew to pullthe rocker shaft (4) from the base of the rockershaft (8).




5. Remove the rocker arms (3), the washers (9), andthe springs (10).

Note: Place an identification mark on each of thecomponents for installation.

6. Remove the adjustment screws (1) and the nuts(2) from rocker arms (3).

7. Inspect all of the components for wear or fordamage. Refer to the Specifications Manual,“Rocker Shaft”. If any of the components are wornor damaged, use new parts for replacement.

Disassembly Procedure (403C-15,403C-17, 404C-22 and 404C-22Tengines)Start By:

a. Remove the rocker shaft and the pushrods. Referto Disassembly and Assembly, “Rocker Shaft andPushrod - Remove”.






Typical example

1. In order to remove the rocker shaft (4), install asuitable M8 setscrew into the end of the rockershaft. Use the setscrew to pull the rocker shaft (4)from the base of the rocker shaft (5).




2. Remove the rocker arms (3), the washers (7), andthe springs (8).

Note: Place an identification mark on each of thecomponents for installation.

3. Remove the O-ring (6) from the rocker shaft (4).

4. Remove the adjustment screws (1) and the nuts(2) from rocker arms (3).

5. Inspect all of the components for wear or fordamage. Refer to the Specifications Manual,“Rocker Shaft”. If any of the components are wornor damaged, use new parts for replacement.

i02801668

Rocker Shaft - Assemble

Assembly Procedure (402C-05,403C-07, 403C-11 and 404C-15engines)



Note: The assembly procedure is similar for thetwo cylinder, the three cylinder and the four cylinderengines. The illustration shows a three cylinderengine.

1. Lubricate the adjustment screw (1) with cleanengine oil. Install the adjustment screw (1) and thenut (2) to the rocker arm (3). Repeat the processfor the remaining rocker arms.


2. Lubricate the rocker shaft (4) with clean engineoil. Position the end of the rocker shaft into thebore in the base of the rocker shaft (8).

For 402C-05 engines, align the two recesses (notshown) in the rocker shaft with the holes in thebase of the rocker shaft (8).

For 403C-07, 403C-11 and 404C-15 engines,align the hole (10) in the rocker shaft with the hole(9) in the base of the rocker shaft (8).



3. Gradually insert the rocker shaft (4) into the baseof the rocker shaft (8). Install the rocker arm (3).




4. Continue to insert the rocker shaft (4) and installthe following components to the rocker shaft:

• Rocker arm (3)

• Washer (9)

• Spring (10)

• Washer (9)

• Rocker arm (3)

5. Repeat Steps 4 and 3 in order to install theremaining components.

6. Ensure that the rocker shaft (4) is fully engagedinto the base of the rocker shaft (8). Check thatthe alignment of the rocker shaft is correct.

7. For 403C-07, 403C-11 and 404C-15 engines,apply 21820117 POWERPART Threadlock tothe first two threads of the setscrew (7). Installthe setscrew (7) in the hole (9) in the base of therocker shaft. Tighten the setscrew.

Note: Ensure that no 21820117 POWERPARTThreadlock is allowed to contaminate the oil galleryin the rocker shaft.

8. Install a new O-ring (5) to the threaded plug (6).

9. Install the threaded plug (6) to the base of therocker shaft (9). Tighten the plug to a torque of15 N·m (11 lb ft).

End By:

a. Install the rocker shaft and the pushrods. Refer toDisassembly and Assembly, “Rocker Shaft andPushrod - Install”.

Assembly Procedure (403C-15,403C-17, 404C-22 and 404C-22Tengines)



Note: The assembly procedure is similar for the threecylinder and the four cylinder engines. The illustrationshows a four cylinder engine.

1. Lubricate the adjustment screw (1) with cleanengine oil. Install the adjustment screw (1) and thenut (2) to the rocker arm (3). Repeat the processfor the remaining rocker arms.


2. Install a new O-ring (8) onto the rocker shaft (4).Lubricate the rocker shaft with clean engine oil.

3. Position the end of the rocker shaft (4) into thebore in the base of the rocker shaft (7). Align therecesses (5) on the rocker shaft with the holes (6)in the base of the rocker shaft (7).



4. Gradually insert the rocker shaft (4) into the baseof the rocker shaft (7). Install the rocker arm (3).




5. Continue to insert the rocker shaft (4) and installthe following components to the rocker shaft:

• Rocker arm (3)

• Washer (9)

• Spring (10)

• Washer (9)

• Rocker arm (3)

6. Repeat Steps 4 and 3 in order to install theremaining components.

7. Ensure that the rocker shaft (4) is fully engagedinto the base of the rocker shaft (7). Check thatthe recesses (5) on the rocker shaft are alignedwith the holes (6) in the base of the rocker shaft.

End By:

a. Install the rocker shaft and the pushrods. Refer toDisassembly and Assembly, “Rocker Shaft andPushrod - Install”.

i02801669

Rocker Shaft and Pushrod -Install






Typical example

1. Install the joint (9) to the base of the rocker shaftassembly (8).

2. Lubricate the pushrods (6) with clean engine oil.Install the pushrods (6) in the cylinder head (7).Ensure that the pushrods are installed correctly inthe socket of the valve lifters.

Note: If the pushrods have been used, ensure thatthe pushrods are installed in original positions.

3. Lubricate the top of the valve stems (5) with cleanengine oil. Install the caps (not shown) on the topof the valve stems.

Note: If the caps have been used, ensure that thecaps are installed in original positions.

4. Lubricate the adjustment screws (3) on eachrocker arm with clean engine oil before installation.Install the rocker shaft assembly (4) to the cylinderhead (7).

Note: Ensure that the ends of the adjustment screwson each rocker arm are correctly seated in the endsof the pushrods (6).

5. Install the setscrews (1) and the nuts (2).

6. Evenly tighten the nuts (2).

Note: The tightening sequence moves from thecenter of the rocker shaft outward.

7. For 402C-05 and 403C-07 engines, tighten thesetscrews (1) and the nuts (2) to a torque of10 N·m (89 lb in).



For 403C-11 and 404C-15 engines, tighten thesetscrews (1) to a torque of 10 N·m (89 lb in).Tighten the nuts (2) to a torque of 23 N·m (17 lb ft).

For 403C-15, 403C-17, 404C-22 and 404C-22Tengines, tighten the setscrews (1) to a torque of10 N·m (89 lb in). Tighten the nuts (2) to a torqueof 33 N·m (24 lb ft).

8. Adjust the valve lash. Refer to Testing andAdjusting, “Engine Valve Lash - Inspect/Adjust” forthe correct procedure to adjust the valve lash.

End By:

a. Install the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover - Remove and Install”.

b. Install the engine oil line. Refer to Disassemblyand Assembly, “Engine Oil Line- Remove andInstall”.

i02801670

Cylinder Head - Remove


a. Remove the water pump. Refer to Disassemblyand Assembly, “Water Pump - Remove”.

b. Remove the exhaust manifold. Refer toDisassembly and Assembly, “Exhaust Manifold-Remove and Install”.

c. Remove the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover - Remove and Install”.

d. Remove the rocker shaft and the pushrods. Referto Disassembly and Assembly, “Rocker Shaft andPushrod - Remove”.

e. Remove the fuel injection lines. Refer toDisassembly and Assembly, “Fuel Injection Lines- Remove and Install”.

f. Remove the fuel injectors. Refer to Disassemblyand Assembly, “Fuel Injectors - Remove”.

g. Remove the oil line. Refer to Disassembly andAssembly, “Engine Oil Line - Remove and Install”.






Typical example

g01116726Illustration 101Typical example for the 2 cylinder head





Typical example for the 4 cylinder head

1. Loosen the cylinder head bolts (1) in reverse orderas this will help prevent distortion of the cylinderhead (2).

For the 402C-05 engine, gradually loosen thecylinder head bolts (1) in the reverse order that isshown in illustration 101.

For the 403C-07, 403C-11, 403C-15 and 403C-17engines, gradually loosen the cylinder head bolts(1) in the reverse order that is shown in illustration102.

For the 404C-15, 404C-22 and 404C-22T engines,gradually loosen the cylinder head bolts (1) in thereverse order that is shown in illustration 103.

Note: Do not use a pry bar to separate the cylinderhead from the cylinder block . Use a rubber mallet toloosen the cylinder head from the cylinder block.

2. Attach a suitable lifting device to the cylinderhead (2). Carefully lift the cylinder head (2) off thecylinder block (3).

Note: Avoid contamination of the cylinder bores withcoolant or with debris.

3. Remove the cylinder head gasket from the cylinderblock (3) or the cylinder head (2). Do not reuse theold cylinder head gasket for the cylinder head (2).

Note: Place the cylinder head on a surface that willnot scratch the face of the cylinder head.

Note: The old gasket for the cylinder head shouldbe used for identification. Head gaskets of differentthickness are available. Refer to Specifications,“Cylinder Head”. The piston height relative to thecylinder head is controlled by the thickness ofthe head gasket. Refer to Testing and Adjusting,“Cylinder Head - Inspect”.

4. If necessary, remove the cylinder head dowelsfrom the cylinder block (3). Use a suitable puller toremove the cylinder head dowels.

5. Inspect the cylinder head (2). Refer to Testing andAdjusting, “Cylinder Head - Inspect” and Testingand Adjusting, “Valve Depth - Inspect”.

i02801671

Cylinder Head - Install





Typical example

1. Thoroughly clean the top of cylinder block (3) andthe bottom of the cylinder head (2). Ensure thatthere is no debris in the cylinder bores.

2. If necessary, install the dowels (6) to the cylinderblock (3).




3. Install suitable guide studs (not shown) to thecylinder block (3). Place the cylinder head gasket(4) over the guide studs and align the gasket (4)with the dowels (6) in the cylinder block (3).

Note: The old gasket for the cylinder head shouldbe used for identification. Head gaskets of differentthickness are available. Refer to Specifications,“Cylinder Head”. The piston height relative to thecylinder head is controlled by the thickness ofthe head gasket. Refer to Testing and Adjusting,“Cylinder Head - Inspect”.

Note: A four digit number is stamped on cylinderhead gasket (4) at location (5). This number shouldface the cylinder head in order to ensure the correctpositioning of the cylinder head gasket. Do not useany gasket sealant or compound on the cylinderhead gasket.

4. Attach a suitable lifting device to the cylinder head(2).

5. Install the cylinder head (2) to the cylinder block(3). Check that the cylinder head is positionedcorrectly.

6. Lubricate the cylinder head bolts (1) with cleanengine oil.



Typical example for the 3 cylinder head


7. Install the cylinder head bolts (1) finger tight.

For 402C-05 engines, tighten the cylinder headbolts to a torque of 36.5 N·m (26.9 lb ft). Use thenumerical sequence that is shown in illustration106.





For 403C-15 and 403C-17 engines, tighten thecylinder head bolts to a torque of 100.5 N·m(74.1 lb ft). Use the numerical sequence that isshown in illustration 107.


For 404C-22 and 404C-22T engines, tighten thecylinder head bolts to a torque of 100.5 N·m(74.1 lb ft). Use the numerical sequence that isshown in illustration 108.

End By:

a. Install the rockershaft and pushrods. Refer toDisassembly and Assembly, “ Rockershaft andPushrods - Remove and Install”.

b. Install the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover - Remove and Install”.

c. Install the water pump. Refer to Disassembly andAssembly, “Water Pump - Install”.

d. Install the oil line. Refer to Disassembly andAssembly, “Engine Oil Line - Remove and Install”.

e. Install the exhaust manifold. Refer to Disassemblyand Assembly, “Exhaust Manifold - Remove andInstall”.

f. Install the fuel injectors. Refer to Disassembly andAssembly, “Fuel Injectors - Remove and Install”.

g. Install the fuel injection lines. Refer to Disassemblyand Assembly, “Fuel Injection lines - Remove andInstall”.

i02187977

Lifter Group - Remove andInstall


a. Remove the cylinder head assembly. Refer toDisassembly and Assembly, “Cylinder Head -Remove”.



Note: Mark the original location of the lifters for laterinstallation.


1. Use a suitable telescopic magnet (1) to removethe lifter (2) from the cylinder block.

2. Inspect the lifter (2) for wear or damage. If thelifter (2) is worn or damaged, use a new part forreplacement.

3. Repeat Steps 1 and 2 for the remaining lifters.







1. Ensure that the lifter (2) is clean and that the oilhole (3) in the lifter (2) is not restricted. Lubricatethe lifter (2) with clean engine oil and install thelifter (2) in the cylinder block.

Note: Ensure that the lifters (2) are installed in theoriginal location. If the camshaft has been replaced,install new lifters (2). Do not install worn lifters to anew camshaft.

2. Repeat Step 1 for the remaining lifters.

End By:

a. Install the cylinder head assembly. Refer toDisassembly and Assembly, “Cylinder Head -Install”.

i02801672

Camshaft - Remove


a. Remove the lifters. Refer to Disassembly andAssembly, “Lifter Group - Remove and Install”.

b. Remove the engine front housing. Refer toDisassembly and Assembly, “Housing (Front) -Remove”.

c. Remove the fuel priming pump. Refer toDisassembly and Assembly, “Fuel Priming Pump- Remove”.






Typical example

1. Remove the slider (1) from the camshaft gear (4).

2. Before the idler gear is removed, rotate thecrankshaft until the timing marks (2) on thefollowing components are aligned.

• Crankshaft gear (3)

• Camshaft gear (4)

• Idler gear (5)

3. Remove the idler gear (5). Refer to Disassemblyand Assembly, “Engine Oil Pump - Remove”.




4. Rotate the camshaft gear (4) in order to align theaccess hole (8) in the camshaft gear with thefastener for the camshaft retainer (9).

Note: The two cylinder and the three cylinder engineshave a different type of camshaft retainer (9) to thefour cylinder engines. The removal procedure isidentical for all models.

For 402C-05, 403C-07, 403C-11, 403C-15,403C-17 and 404C-15 engines, remove the outersetscrew (6) and remove the allen head screw (7).

For 404C-22 and 404C-22T engines, remove theouter setscrew (6) and remove the setscrew (7)from the camshaft retainer (9).

5. Remove the camshaft retainer (9).


6. Carefully remove the camshaft assembly (10)from the cylinder block (11). Be careful not todamage the lobes of the camshaft or the camshaftbearings.

7. Inspect the components for wear or damage.Refer to specifications, “Camshaft” for details ofthe camshaft lobes. Replace any components thatare worn or damaged.

i02196165

Camshaft - Disassemble


a. Remove the camshaft assembly. Refer toDisassembly and Assembly, “Camshaft -Remove”.




1. Use a suitable puller to remove the camshaft gear(5) from the camshaft (1).

Note: The camshaft gear should be positioned on asuitable support in order to prevent damage to thegovernor flyweights during disassembly.



2. Remove the spacer (4) and the woodruff key (2)from the camshaft (1).

3. Use a suitable puller to remove the front camshaftbearing (3) from the camshaft (1).

Note: Identify the orientation of the camshaft bearing(3) for installation.

4. Inspect all of the components for wear or damage.Replace any components that are worn ordamaged.

i02196164

Camshaft - Assemble

Assembly Procedure




Typical example

1. Ensure that the camshaft (1) is clean. Lubricatethe front end of the camshaft with clean engine oil.Use a suitable press to install the front camshaftbearing (3) to the camshaft.

Note: Ensure that the camshaft bearing (3) isinstalled in the correct orientation. The camshaftbearing should be pressed squarely onto thecamshaft or damage to the bearing may occur.

2. Install the spacer (4) and the woodruff key (2) tothe camshaft (1).

3. Align the camshaft gear (5) with the woodruff key(2) on the camshaft (1). Use a suitable press toinstall the camshaft gear to the camshaft.

Note: The camshaft gear should be positioned on asuitable support in order to prevent damage to thegovernor flyweights during installation.

End By:

a. Install the camshaft assembly. Refer toDisassembly and Assembly, “Camshaft - Install”.

i02801686

Camshaft - Install




1. Ensure that the camshaft is clean. Lubricate thecamshaft with clean engine oil.




2. Carefully install the camshaft assembly (10) intothe engine cylinder block (11). Be careful not todamage the lobes of the camshaft or the camshaftbearings.


Typical example

3. Install the camshaft retainer (9).

Note: The two cylinder and the three cylinder engineshave a different camshaft retainer (9) and fasteners(6) and (7), to the four cylinder engines. The removalprocedure is similar for all models.

4. Align the holes in the camshaft retainer (9) withthe holes in the cylinder block (11).

For 402C-05, 403C-07, 403C-11, 403C-15,403C-17 and 404C-15 engines, install the outersetscrew (6) and install the allen head screw (7).

For 404C-22 and 404C-22T engines, install thesetscrews (6) and (7).

Torque both fasteners to 11 N·m (8 lb ft).


5. Install the idler gear (5). Refer to Disassembly andAssembly, “Engine Oil Pump - Install”.

Note: When you install the idler gear, ensurethat timing marks (2) are aligned on the followingcomponents.

• Crankshaft gear (3)

• Camshaft gear (4)

• Idler gear (5)

Number one piston will now be in the top deadcenter position.

6. Install the slider (1) to the camshaft (4).

Note: Ensure that the notch on the base of the slider(1) is engaged on the pin of the camshaft gear (4).

End By:

a. Install the engine front housing. Refer toDisassembly and Assembly, “Housing (Front) -Install”.

b. Install the fuel priming pump. Refer to Disassemblyand Assembly, “Fuel Priming Pump - Install”.

c. Install the lifters. Refer to Disassembly andAssembly, “Lifter Group- Remove and Install”.

i02186340

Engine Oil Pan - Remove andInstall

Removal Procedure





Note: The two cylinder, the three cylinder and thefour cylinder engines have different engine oil pans.The removal procedure is identical for all models.




1. Remove the drain plugs (5) from the engine oil pan(2). Drain the engine oil into a suitable containerfor storage or disposal. Refer to Operation andMaintenance Manual, “Refill Capacities” for theapproximate capacity of the lubricating oil system.

2. Remove the sealing washers (3) from the drainplugs (5). Discard the sealing washers.

3. Remove the setscrews (4) for the engine oil pan(2).

4. Remove the engine oil pan (2) from the engine.

5. Remove the joint (1) from the engine oil pan andthe cylinder block. Discard the joint.




Note: The two cylinder, the three cylinder and thefour cylinder engines have different engine oil pans.The installation procedure is identical for all models.


1. Clean all surfaces thoroughly.

2. Install a new joint (1) to the engine. Install theengine oil pan (2) to the engine.

3. Install the setscrews (4) for the engine oil pan (2).Tighten the setscrews for the engine oil pan to atorque of 11 N·m (8 lb ft).

4. Install the drain plugs (5) and new sealing washers(3) to the oil pan (2). Tighten the drain plugs to atorque of 34 N·m (25 lb ft).

5. Fill the engine oil pan to the correct level that isindicated on the engine oil level gauge. Referto Operation and Maintenance Manual, “RefillCapacities” for more information.

i02189003

Pistons and Connecting Rods- Remove


a. Remove the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head - Remove”.

b. Remove the engine oil pan. Refer to Disassemblyand Assembly, “Engine Oil Pan - Remove andInstall”.

c. Remove the oil suction pipe. Refer to Disassemblyand Assembly, “Engine Oil Pump - Remove”.





1. Position the piston that is being removed in thebottom center position.


2. Remove the carbon buildup from the inner surfaceof the top of the cylinder bore.

3. Ensure that the connecting rod and the cap arecorrectly marked to the cylinder.

Note: Do not punch the connecting rod or stamp theconnecting rod assembly as this may cause damage.

4. Remove the nuts (6) from the connecting rod (1).

5. Remove the connecting rod cap (5) with thebearing shell (3).

Note: Use tape or rubber tubing on connecting rodbolts (2) to protect the crankshaft journals. The sharpedges of the connecting rod bolts could damage thecrankshaft journals.

6. Push the piston and connecting rod (1) away fromthe crankshaft until the piston rings are out of thecylinder bore. Remove the piston from the cylinderblock.

Note: Make a mark under the piston on the pin bossin order to identify the cylinder. Always mark the frontpin boss to aid installation.

7. Remove connecting rod bearings (3) fromconnecting rod (1) and connecting rod cap (5).

8. Keep connecting rods (1) and connecting rod caps(5) together. Ensure that the identification marksare on the connecting rod and on the connectingrod cap. This will ensure that the piston is installedinto the correct cylinder in the cylinder block.

9. Repeat Steps 1 through 8 for removing theremaining pistons and connecting rods.

i02189019

Pistons and Connecting Rods- Disassemble


a. Remove the pistons and the connecting rods.Refer to Disassembly and Assembly, “Pistons andConnecting Rods - Remove”.

NOTICERemoval of the piston pin bushing must be carriedout by personnel with the correct training. Also spe-cial machinery is required. For more information referto your authorized Perkins dealer or your Perkins dis-tributor.






Typical example

1. Use suitable pliers in order to remove the circlips(2).

2. Remove the piston pin (3) from the piston (4).

Note: If the piston pin cannot be removed by hand,heat the piston to a temperature of 45 ± 5 °C(113 ± 9 °F). Do not use a oxyacetylene torch to heatthe piston. Mark the piston pin for installation.


Typical example

3. Use a suitable ring expander in order to removethe piston rings (7) and (6), and the oil control ring(5) from the piston (4).

Note: Identify the orientation of the piston rings forinstallation.




Typical example

4. Remove the nuts (8) for the connecting rod cap(9). Remove the connecting rod cap (9) fromthe connecting rod (1). Remove the bearingshells (10) from the connecting rod (1) and theconnecting rod cap (9).


5. Use a suitable press and a suitable adapter inorder to remove the piston pin bushing (11) fromthe connecting rod (1).

i02189011

Pistons and Connecting Rods- Assemble

Assembly Procedure



NOTICEInstallation of the piston pin bushing must be carriedout by personnel with the correct training. Also specialmachinery is required.

1. If the piston pin bushing was removed, refer toyour authorized Perkins dealer or your Perkinsdistributor for assistance.


2. Align the identification marks (2) on the connectingrod (1) and the piston (5).



Note: The Shibaura name inside the piston mustalign with the stamped number on the connecting rod.

3. Lubricate the piston pin (4) with clean engine oil.Install the piston pin (4) into the piston (5) and theconnected rod (1).

Note: If the piston pin cannot be installed by hand,heat the piston to a temperature of 45° ± 5°C(113° ± 9°F).

4. Use suitable pliers to install the two circlips (3).Ensure that the circlips are seated into the groovesin the piston (5).


Typical example

Note: Refer to Specifications, “Pistons and Rings” formore information on piston identification.

g01114373Illustration 128typical example

5. Use a suitable ring expander to install the pistonrings onto the piston (5). Use the followingprocedure to install the piston rings onto thepiston.

a. Install the oil control ring (6) in the groove thatis lowest on the piston (5). The latch pin (10)that is on the oil control ring (6) must be insidethe ends of spring (11).

Note: Ensure that the latch pin that is on the oilcontrol ring is 180 degrees from the oil control ringgap.


b. Install the intermediate piston ring (7) with thetapered face into the second groove on thepiston. The step (12) must be toward the topof the piston.



c. Install the top piston ring (8) with the barrelface and the molybdenum insert into the topgroove on the piston.

d. Lubricate the piston rings with clean engine oil.Position the piston ring gaps (9) at 90 degreesaway from each other.

End By:

a. Install the pistons and the connecting rods.Refer to Disassembly and Assembly, “Piston andConnecting Rods - Install”.

i02801688

Pistons and Connecting Rods- Install




1. Thoroughly clean all of the components.

Note: Refer to Disassembly and Assembly,“Connecting Rod Bearings - Install” for the inspectionprocedure of the connecting rod bearings and thecrankshaft connecting rod journals.

2. Apply clean engine oil to the following components:

• Crankshaft journals

• Inside of the cylinder bores

• Piston rings

• Connecting rod bearings

Note: The piston and the connecting rod are matchedto a specific cylinder. Ensure that the connecting rodand the pistons are installed in the correct cylinder.

Note: Do not punch the connecting rod or stamp theconnecting rod assembly as this may cause damage.

3. Rotate the crankshaft until the bearing journal isat the bottom center.


Typical example

4. Use a suitable piston ring compressor (1) in orderto compress the piston rings.

For the 402C-05 and 403C-07 engines, the pistonring compressor should be suitable for a piston67 mm (2.64 inch).

For the 403C-11 and 404C-15 engines, the pistonring compressor should be suitable for a piston77 mm (3.03 inch) in diameter.

For the 403C-15, 403C-17, 404C-22 and404C-22T engines, the piston ring compressorshould be suitable for a piston 84 mm (3.31 inch)in diameter.

Note: Move the piston rings on the pistons untilthe ring openings are separated by approximately90 degrees. Refer to Disassembly and Assembly,“Pistons and Connecting Rods - Assemble”.




5. Put the piston and the connecting rod in thecylinder bore. Align the identification marks on thetop of the piston to the front of the cylinder block.Align the identification marks (3) on the side ofthe connecting rod to the right side of the cylinderblock.

Note: The right side is determined from the flywheelend of the engine.

Note: Ensure that the piston ring compressor (1) isinstalled correctly in order to allow the piston and theconnecting rod to easily slip into the cylinder block.Use tape or rubber tubing on the connecting rod boltsto protect the crankshaft journals.

6. Align the piston and the connecting rod assemblywith the crankshaft. Use a soft faced hammer (2)to tap the piston into the cylinder bore until thepiston ring compressor (1) comes off the piston.


7. Push the piston and the connecting rod assemblyinto the cylinder. Guide the connecting rodassembly onto the connecting rod journal.

8. Install the connecting rod cap (4) and theconnecting rod nuts (5).

For the 402C-05 and 403C-07 engines, tightenthe nuts (5) for the connecting rod cap (4) to atorque of 23 N·m (16 lb ft).

For the 403C-11 and 404C-15 engines, tighten thenuts (5) for the connecting rod cap (4) to a torqueof 32 N·m (24 lb ft).

For the 403C-15, 403C-17, 404C-22 and404C-22T engines, tighten the nuts (5) for theconnecting rod cap (4)to a torque of 52 N·m(38 lb ft).

9. Repeat Steps 1 through 8 for the remainder of thepistons and connecting rods.

10.Rotate the crankshaft in order to ensure that nobinding occurs.

End By:

a. Install the oil suction pipe. Refer to Disassemblyand Assembly, “Engine Oil Pump- Install”.


c. Install the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head - Install”.

i02186176

Connecting Rod Bearings -Remove


a. Remove the engine oil pan. Refer to Disassemblyand Assembly, “Engine Oil Pan - Remove andInstall”.

b. Remove the oil supply tube. Refer to Disassemblyand Assembly, “Crankshaft - Remove”.





Note: The connecting rod and the connecting rod capshould have matching marks (6) on the right handside. Mark the connecting rod (1) and the connectingrod cap (5), if necessary. The right side of the engineis determined from the flywheel end.




Typical example

1. Rotate the crankshaft until the piston is at thebottom center. Remove the connecting rod nuts(4) from the connecting rod bolts (2). Remove theconnecting rod cap (5) from the connecting rod (1).

2. Remove the lower bearing shell (3) of theconnecting rod bearing from the connecting rodcap (5).

3. Carefully push the connecting rod (1) into thecylinder bore. Remove the upper bearing shell (3)of the connecting rod from the connecting rod.

Note: Use tape or rubber tubing on the connectingrod bolts to protect the crankshaft journals. The sharpedges of the connecting rod bolts could damage thecrankshaft journals.

4. Repeat Steps 1 through 3 for the remainingconnecting rod bearings.

i02186171

Connecting Rod Bearings -Install




NOTICEWhen the connecting rod caps are installed, ensurethat the identification marks are aligned.


1. Check the clearance between the connecting rodbearing and the connecting rod bearing journal ofthe crankshaft. Install the connecting rod bearingsdry when the clearance checks are made. Refer toDisassembly and Assembly, “Bearing Clearance- Check” for information on bearing clearancechecks.

2. Clean the bearing surface of the connecting rod(1) and the connecting rod cap (5). Ensure that thenumber (6) on the connecting rod cap (5) alignswith the number (6) on the connecting rod (1).

3. Clean the upper connecting rod bearing (3) andlubricate the bearing face with clean engine oil.

4. Clean the lower connecting rod bearing (3) andlubricate the bearing face with clean engine oil.

Note: Align the tabs on the back of the connecting rodbearings (3) with the tab grooves in the connectingrod (1) and the tab grooves on the connecting rodcap (5).

5. Install the upper connecting rod bearing (3) to theconnecting rod (1).

6. Position the connecting rod (1) against thecrankshaft.

7. Install the lower connecting rod bearing (3) in theconnecting rod cap (5).



8. Install the connecting rod cap (5) in position onthe connecting rod (1) and install the nuts (4) tothe connecting rod bolts (2). Refer to Disassemblyand Assembly, “Pistons and Connecting Rods -Install” for the correct torque of the connecting rodnuts (4).

Note: The identification marks must face the righthand side of the engine for the correct installation.

9. Repeat Steps 2 through 8 for the installation of theremaining connecting rod bearings.

End By:

a. Install the oil supply tube. Refer to Disassemblyand Assembly, “Crankshaft - Install”.


i02801692

Crankshaft Main Bearings -Remove


a. Remove the crankshaft. Refer to Disassembly andAssembly, “Crankshaft - Remove”.



Crankshaft Main Bearings


Note: Mark the halves of the main bearing carriersfor later installation.

1. Remove the setscrews (1) that secure the upperhalf of main bearing cap (2) to the lower half ofmain bearing cap (7).

2. Separate the upper half of main bearing cap (2)from the lower half of main bearing cap (7).

Note: Dowels (5) are installed in each bearing capin order to align the two halves of the main bearingcarrier.

Note: Thrust washers are only installed on the403C-15, 403C-17, 404C-22 and 404C-22T engines.

3. For 403C-15 and 403C-17 engines, remove thelower thrust washers (3).

For 404C-22 and 404C-22T engines, remove thelower thrust washers (3) and the upper thrustwasher (6).

4. Remove the main bearings (4) from the mainbearing caps.

Crankshaft Bearing (Front)Table 8


27610275 Driver Gp 1




1. Remove the bush for the crankshaft (1). UseTooling (2) and a hammer to drive out the bush forthe crankshaft (1) from the inside of the cylinderblock (3).

i02801697

Crankshaft Main Bearings -Install


Crankshaft Main Bearings


1. Install the main bearings (4) into the halves of themain bearing caps.

2. Position the upper half of the main bearing cap (2)in position on the crankshaft. Position the lowerhalf ofthe main bearing cap (7) in position on thecrankshaft.

Note: Refer to the identification marks that havebeen made on the main bearing carriers for correctalignment.

Note: Ensure that the dowels (5) are in the correctposition. This will ensure that the two halves of themain bearing caps are aligned.

Note: Ensure that the lubricating oil holes align withthe oil feed holes in the cylinder block.

Note: Thrust washers are only installed to 403C-15,403C-17, 404C-22 and 404C-22T engines.

3. For 403C-15 and 403C-17 engines, install the twolower thrust washers (3).

For 404C-22 and 404C-22T engines, install thetwo lower thrust washers (3) and the upper thrustwasher (6).

Note: Ensure that the thrust washers are alignedcorrectly and that the oil grooves are facing thecrankshaft.

4. Install the setscrews (1).

For the 402C-05, 403C-07, 403C-11, 403C-15,403C-17 and 404C-15 engines, tighten thesetscrews to a torque of 23 N·m (17 lb ft).

For the 404C-22 and 404C-22T engines, tightenthe setscrews to a torque of 52 N·m (38 lb ft).

Bush for the Crankshaft (Front)Table 9

Required Tools


27610275 Driver Gp 1




1. Install the bush for the crankshaft (1). Use Tooling(6) and a hammer to drive in the bush for thecrankshaft (1) from the outside of the cylinderblock (5).

Note: Ensure that the oil supply hole (4) is alignedwith the oil gallery in the cylinder block (5).

Note: Ensure that the chamfered side (3) of the bushfor the crankshaft (1) is facing toward the cylinderblock (5) and that the joint (2) of the bush for thecrankshaft (1) is facing toward the top of the cylinderblock (5).

End By:

a. Install the crankshaft. Refer to Disassembly andAssembly, “Crankshaft - Install”.

i02192828

Crankshaft - Remove


a. Remove the engine oil relief valve. Refer toDisassembly and Assembly, “Engine Oil ReliefValve - Remove and Install”.

b. Remove the flywheel. Refer to Disassembly andAssembly, “Flywheel - Remove and Install”.

c. Remove the housing for the crankshaft rear seal.Refer to Disassembly and Assembly, “CrankshaftRear Seal - Remove”.

d. Remove the engine oil pump. Refer toDisassembly and Assembly, “Engine Oil Pump- Remove”.

e. Remove the pistons and the connecting rods.Refer to Disassembly and Assembly, “Pistons andConnecting Rods - Remove”.






1. Remove the bolts (3) from the crankcase crossmember.

2. Remove the two allen head screws (2) that arerecessed. The allen head screws are located atthe rear of the engine.

3. Place the rear of the engine in an upward position.Attach a suitable lifting device (1) to the crankshaftand the main bearing assembly (6).

4. Lift the crankshaft (6) and the main bearingassembly from cylinder block (5). Do not scratchany of the finished surfaces on the crankshaft.



i02801706

Crankshaft - Install



Typical example

NOTICEEnsure that the oil passages in themain bearings alignwith the oil passages in the cylinder block.

1. Lower the crankshaft and the main bearingassembly (9) into the cylinder block (8). Donot scratch any of the finished surfaces on thecrankshaft.

2. Align the two setscrew holes (2) in the mainbearing assembly (9) to the two holes in thecylinder block (6).

3. Install the two allen head screws (3) that arerecessed. The allen head screws are located atthe rear of the engine.

Tighten the allen head screws (3) to a torque of27 N·m (20 lb ft).

4. Ensure that the three setscrew holes (7) in themain bearing assembly (9) are aligned to the threeholes (5) in the cylinder block (8).

Note: The third hole in the main bearing assembly(7) is not shown.

5. Install the three setscrews (4) in the holes in thecylinder block (5).



For the 402C-05, 403C-07, 403C-11 and 404C-15engines, tighten the setscrews (4) to a torque of27 N·m (20 lb ft).

For the 403C-15, 403C-17, 404C-22 and404C-22T engines, tighten the setscrews (4) to atorque of 52 N·m (38 lb ft).

6. Check the crankshaft for end play. Force thecrankshaft toward the front of the engine andinsert a feeler gauge between the rear thrustwasher and the crankshaft. Alternatively, install adial indicator to one end of the crankshaft. Forcethe crankshaft to the front of the engine and thenforce the crankshaft to the rear of the engine.Record the variation on the dial indicator. Referto Specifications, “Crankshaft” for the maximumpermissible crankshaft end play.

End By:

a. Install the pistons and the connecting rods. Referto Disassembly and Assembly, “Pistons andConnecting Rods - Install”.

b. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump - Install”.

c. Install the housing for the crankshaft rear seal.Refer to Disassembly and Assembly, “CrankshaftRear Seal - Install”.

d. Install the flywheel. Refer to Disassembly andAssembly, “Flywheel - Install”.

e. Install the engine oil relief valve. Refer toDisassembly and Assembly, “Engine Oil ReliefValve - Remove and Install”.

i01996219

Bearing Clearance - Check

Measurement ProcedureTable 10

Required Tools

Part Description Qty

Plastic Gauge (Green)0.025 to 0.076 mm(0.001 to 0.003 inch)

1

Plastic Gauge (Red)0.051 to 0.152 mm(0.002 to 0.006 inch)

1

Plastic Gauge (Blue)0.102 to 0.229 mm(0.004 to 0.009 inch)

1

Plastic Gauge (Yellow)0.230 to 0.510 mm(0.009 to 0.020 inch)

1



Note: Perkins does not recommend the checking ofthe actual bearing clearances particularly on smallengines. This is because of the possibility of obtaininginaccurate results and the possibility of damaging thebearing or the journal surfaces. Each Perkins enginebearing is quality checked for specific wall thickness.

Note: The measurements should be withinspecifications and the correct bearings shouldbe used. If the crankshaft journals and the boresfor the block and the rods were measured duringdisassembly, no further checks are necessary.However, if the technician still wants to measure thebearing clearances, the use of Plastic Gauge is anacceptable method. Plastic Gauge is less accurateon journals with small diameters if clearances areless than 0.10 mm (0.004 inch).

NOTICELead wire, shim stock or a dial bore gauge can dam-age the bearing surfaces.

The technician must be very careful to use PlasticGauge correctly. The following points must beremembered:



• Ensure that the backs of the bearings and thebores are clean and dry.

• Ensure that the bearing locking tabs are properlyseated in the tab grooves.

• The crankshaft must be free of oil at the contactpoints of the Plastic Gauge.

1. Put a piece of the Plastic Gauge on the crown ofthe bearing that is in the cap.

Note: Do not allow the Plastic Gauge to extend overthe edge of the bearing.

2. Use the correct torque-turn specifications in orderto install the bearing cap. Do not use an impactwrench. Be careful not to dislodge the bearingwhen the cap is installed.

Note: Do not turn the crankshaft when the PlasticGauge is installed.

3. Carefully remove the cap, but do not removethe Plastic Gauge. Measure the width of thePlastic Gauge while the Plastic Gauge is in thebearing cap or on the crankshaft journal. Referto Illustration 141.

g00953605Illustration 141Typical Example

4. Remove all of the Plastic Gauge before you installthe bearing cap.

Note: When the Plastic Gauge is used, the readingscan sometimes be unclear. For example, all parts ofthe Plastic Gauge are not the same width. Measurethe major width in order to ensure that the parts arewithin the specification range. Refer to SpecificationsManual, “Connecting Rod Bearing Journal” andSpecifications Manual, “Main Bearing Journal” for thecorrect clearances.

i02801717

Coolant Temperature Switch -Remove and Install

Removal Procedure (403C-11,403C-15, 403C-17, 404C-15,404C-22, and 404C-22T Engines)





1. Drain the coolant from the cooling system intoa suitable container for storage or disposal.Refer to Operation and Maintenance Manual,“Maintenance Section”.




2. Remove the coolant temperature switch (1) fromthe water temperature regulator housing (2).

3. Clean the coolant temperature switch. Inspectthe coolant temperature switch (1) for damage. Ifthe coolant temperature switch is damaged, usea new part for replacement. For information ontesting the coolant temperature switch for correctoperation, refer to Testing and Adjusting, “CoolantTemperature Switch - Test”.

Removal Procedure (402C-05, and403C-07 Engines)





1. Drain the coolant from the cooling system intoa suitable container for storage or disposal.Refer to Operation and Maintenance Manual,“Maintenance Section”.


2. Remove the coolant temperature switch (1) fromthe water pump housing (2).

3. Clean the coolant temperature switch. Inspectthe coolant temperature switch (1) for damage. Ifthe coolant temperature switch is damaged, usea new part for replacement. For information ontesting the coolant temperature switch for correctoperation, refer to Testing and Adjusting, “CoolantTemperature Switch - Test”.

Installation Procedure (403C-11,403C-15, 403C-17, 404C-15,404C-22, and 404C-22T Engines)




1. If a used coolant temperature switch is installed,apply 21820122 POWERPART Pipe sealant tothe threads of the coolant temperature switch (1).

2.



3. Install the coolant temperature switch (1) intothe water temperature regulator housing. Tightenthe coolant temperature switch (1) to a torque of27 N·m (20 lb ft).

4. Fill the cooling system with coolant to the correctlevel. Refer to Operation and MaintenanceManual, “Refill Capacities” for additionalinformation.

Installation Procedure (402C-05,and 403C-07 Engines)




1. If a used coolant temperature switch is installed,apply 21820122 POWERPART Pipe sealant tothe threads of the coolant temperature switch (1).

2. Install the coolant temperature switch (1) intothe water pump housing (2). Tighten the coolanttemperature switch (1) to a torque of 27 N·m(20 lb ft).

3. Fill the cooling system with coolant to the correctlevel. Refer to Operation and MaintenanceManual, “Refill Capacities” for additionalinformation.

i02195380

Engine Oil Pressure Switch -Remove and Install

Removal Procedure





Note: The engine oil pressure switch can be locatedin one of two positions. The oil pressure switch canbe located in the valve mechanism cover (1), or inthe cylinder block (2). Refer to Specifications Manual,“Engine Oil Pressure Switch” for the correct location.




Typical example

1. If the oil pressure switch is located in the valvemechanism cover, remove the engine oil pressureswitch.

If the oil pressure switch is located in the cylinderblock, remove the engine oil pressure switchand adapter assembly. Remove the engine oilpressure switch from the adapter.

2. Clean the oil pressure switch.

Installation ProcedureNote: The engine oil pressure switch can be locatedin one of two positions. The oil pressure switch canbe located in the valve mechanism cover (1), or inthe cylinder block (2). Refer to Specifications Manual,“Engine Oil Pressure Switch” for the correct location.


Typical example

1. If a used engine oil pressure switch is installed,apply a thin layer of 21820122 POWERPARTPipe sealant to the threads of the engine oilpressure switch.

2. If the oil pressure switch is located in the valvemechanism cover, install the engine oil pressureswitch (1). Tighten the oil pressure switch to atorque of 11 N·m (8.1 lb ft).

If the oil pressure switch is located in the cylinderblock (2), install the engine oil pressure switchto the adapter. Tighten the engine oil pressureswitch to a torque of 23 N·m (16.9 lb ft). Install theadapter and oil pressure switch assembly to thecylinder block. Tighten the adapter to a torque of11 N·m (8.1 lb ft).



i02801718

Glow Plugs - Remove andInstall


a. Remove the fuel injection lines, if necessary. Referto Disassembly and Assembly, “Fuel InjectionLines - Remove and Install”.

Disconnect batteries before performance of anyservice work.




1. Remove the nuts (1) and the washers (2) from thebus bar (3) on the glow plugs (4).

2. Remove the bus bar (3) from the glow plugs (4).

3. Remove the glow plugs (4) from the cylinder head.





1. Install the glow plugs (4) in the cylinder head.

For the 402C-05,402C-07,403C-11 and 404C-15engines, tighten the glow plugs to a torque of11.5 N·m (8.5 lb ft).

For the 403C-15,403C-17,404C-22 and 404C-22Tengines, tighten the glow plugs to a torque of17.5 N·m (13 lb ft).

2. Install the bus bar (3) on the glow plugs (4).

3. Install the washers (2) and the nuts (1) on theglow plugs (4). Tighten the nuts (1) to a torqueof 1.2 N·m (10.6 lb in).

End By:

a. Install the fuel injection lines, if necessary. Refer toDisassembly and Assembly, “Fuel Injection Lines- Remove and Install”.

i02196372

V-Belts - Remove and Install

Removal Procedure






Typical example

1. Loosen setscrew (1) and setscrew (2). Loosen thefasteners (4) on the alternator (3).

2. Push the alternator (3) toward the engine andremove the V-belt (5).





1. Check the condition of the V-belt (5). If theV-belt is worn or damaged, use a new V-belt forreplacement.

2. Install the V-belt (5) in position on the engine.

3. Slide the alternator (3) away from the engine.Tighten the setscrew (1) and setscrew (2) toa torque of 25.5 N·m (18.8 lb ft). Tighten thefasteners (4) to a torque of 25.5 N·m (18.8 lb ft) forthe alternator (3). Refer to Testing and Adjusting,“Belt Tension Chart” for more information on thecorrect belt tension.

i02801722

Fan - Remove and Install

Removal Procedure (404C-22 and404C-22T Engines)Start By:

a. Remove the V-Belts. Refer to Disassembly andAssembly, “V-Belts - Remove and Install”.




Typical example

1. Remove the four setscrews (1) from the fan (2)and remove the fan (2) from the adapter (4).

2. Remove the four allen head screws (3) that securethe adapter (4) and the pulley (5) to the waterpump (6).

3. Remove the adapter (4) and the pulley (5) fromthe water pump (6).

Removal Procedure (402C-05,403C-07, 403C-11, 403C-15,403C-17 and 404C-15 Engines)Start By:





Typical example

1. Remove the four setscrews (1) that secure the fan(2), the spacer (3) and the pulley (4) to the waterpump (5).

2. Remove the fan (2), the spacer (3) and the pulley(4) from the water pump (5).



Installation Procedure (404C-22and 404C-22T Engines)


Typical example

1. Install the pulley (5) and the adapter (4) in positionon the water pump (6) and ensure that thesetscrew holes are aligned.

2. Install the four allen head screws (3) in positionon the adapter (4) and align the setscrews withthe setscrew holes in pulley (5) and the setscrewholes in the water pump (6). Tighten the four allenhead screws (3) to a torque of 10 N·m (7 lb ft).

3. Position the fan (2) so that the setscrew holesalign with the setscrew holes in adapter (4).

4. Install the four setscrews (1) onto the fan (2) andhand tighten the setscrews.

5. Tighten the four setscrews (1) to a torque of11 N·m (8 lb ft).

End By:

a. Install the V-Belts. Refer to Disassembly andAssembly, “V-Belts - Remove and Install” .



Installation Procedure (402C-05,403C-07, 403C-11, 403C-15, 403C-17and 404C-15 Engines)


1. Install the pulley (4), the spacer (3) and the fan (2)in position on the water pump (5) and ensure thatthe setscrew holes are aligned.

2. Install the four setscrews (1) into the fan (2), thespacer (3) and the pulley (4) and hand tighten thesetscrews.

3. Tighten the four setscrews to a torque of 11 N·m(8 lb ft).

End By:

a. Install the V-Belts. Refer to Disassembly andAssembly, “V-Belts - Remove and Install” .

i02196771

Alternator - Remove and Install

Removal Procedure for the 14 AMPAlternatorStart By:


Note: Disconnect all electrical connections to thealternator before proceeding. Mark the connectionsor identify the connections for future installation.




Typical example

1. Remove the bolt (1), the washer (3) and the nut(4) from the alternator (2).

2. Remove the setscrew (5) that fastens thealternator (2) to the engine.

3. Remove the alternator (2) from the engine.







Typical example

1. Remove the bolt (1), the washer (3) and the nut(4) from the alternator (2).

2. Remove the setscrew (5) that fastens thealternator (2) to the engine.








Typical example

1. Remove the setscrew (6), the washer (5) and thespacer (1) from the alternator (2).

2. Remove the setscrew (4) and the washer (3) thatfastens the alternator (2) to the engine.








Typical example

1. Remove the setscrew (1) and the washer (2) fromthe alternator (3).

2. Remove the two bolts (6), the two washers (5)and the two nuts (4) that fasten the alternator (3)to the engine.


Removal Procedure for the 65 AMPand the 85 AMP AlternatorStart By:






Typical example

1. Remove the setscrew (2) and the washer (1) fromthe alternator (3).

2. Remove the bolt (4), the washer (5) and the nut(6) that fastens the alternator (3) to the engine.




Installation Procedure for the 14AMP Alternator


Typical example

1. Position the alternator (2) on the engine.

2. Install the setscrew (5) that fastens the alternator(2) to the engine.

3. Install the bolt (1), the washer (3) and the nut (4)to the alternator (2).

4. Hand tighten the setscrew (5), the bolt (1) and thenut (4) on the alternator (2).

Note:When you install the alternator, ensure that thealternator pulley is in alignment with the crankshaftpulley within one degree.

Note: Reconnect all electrical connections to thealternator before operating the engine.

End By:

a. Install the V-Belts. Refer to Disassembly andAssembly, “V-Belts - Remove and Install”.





Typical example


2. Install the setscrew (5) that fastens the alternator(2) to the engine.

3. Install the bolt (1), the washer (3) and the nut (4)to the alternator (2).

4. Hand tighten the setscrew (5), the bolt (1) and thenut (4) on the alternator (2).



End By:






Typical example


2. Install the setscrew (4) and the washer (3) thatfastens the alternator (2) to the engine.

3. Install the setscrew (6), the washer (5) and thespacer (1) to the alternator (2).

4. Hand tighten the setscrew (4) and the setscrew(6) on the alternator (2).



End By:






Typical example


2. Install the two bolts (6), the two washers (5) andthe two nuts (4) that fasten the alternator (3) onthe engine.

3. Install the setscrew (1) and the washer (2) to thealternator (3).

4. Hand tighten the two bolts (6), the two nuts (4)and the setscrew (1) on the alternator (3) .



End By:




Installation Procedure for the 65AMP and the 85 AMP Alternator


Typical example


2. Install the bolt (4), the washer (5) and the nut (6)that fastens the alternator (3) to the engine.

3. Install the setscrew (2) and the washer (1) to thealternator (3).

4. Hand tighten the bolt (4), the nut (6) and thesetscrew (2) on the alternator (3).



End By:


i02801726

Electric Starting Motor -Remove and Install


a. Disconnect all electrical connections to theelectric starting motor before proceeding. Markall connections or identify all connections for laterinstallation.




1. Remove the fasteners (1) that secure the electricstarting motor (2) to the engine.

For the 403C-11, 403C-15, 403C-17, 404C-15,404C-22 and 404C-22T engines, the electricstarting motor is secured to the engine with bolts,washers and nuts (not shown).

For the 402C-05 and 403C-07 engines, theelectric starting motor is secured to the enginewith setscrews and washers.

2. Remove the electric starting motor (2) from theengine.



Typical example

1. Install the electric starting motor (2) in position onthe engine.

2. Install the fasteners (1) that secure the electricstarting motor (2) to the engine.

For the 403C-11, 403C-15, 403C-17, 404C-15,404C-22 and 404C-22T engines, the electricstarting motor is secured to the engine with bolts,washers and nuts (not shown).

For the 402C-05 and 403C-07 engines, theelectric starting motor is secured to the enginewith setscrews and washers.

Tighten the fasteners to a torque of 50 N·m(36.9 lb ft).

End By:

a. Reconnect all electrical connections to the electricstarting motor before you operate the engine.


SENR9973-01 103Index Section

Index

A

Alternator - Remove and Install ............................. 91Installation Procedure for the 14 AMPAlternator.......................................................... 97Installation Procedure for the 15 AMPAlternator.......................................................... 98Installation Procedure for the 40 AMPAlternator.......................................................... 99Installation Procedure for the 55 AMPAlternator........................................................ 100Installation Procedure for the 65 AMP and the 85AMP Alternator............................................... 101Removal Procedure for the 14 AMP Alternator.. 91Removal Procedure for the 15 AMP Alternator.. 92Removal Procedure for the 40 AMP Alternator.. 93Removal Procedure for the 55 AMP Alternator.. 94Removal Procedure for the 65 AMP and the 85AMP Alternator................................................. 95

B

Bearing Clearance - Check ................................... 81Measurement Procedure ................................... 81

C

Camshaft - Assemble ............................................ 66Assembly Procedure.......................................... 66

Camshaft - Disassemble ....................................... 65Disassembly Procedure ..................................... 65

Camshaft - Install................................................... 66Installation Procedure ........................................ 66

Camshaft - Remove............................................... 64Removal Procedure ........................................... 64

Connecting Rod Bearings - Install ......................... 75Installation Procedure ........................................ 75

Connecting Rod Bearings - Remove..................... 74Removal Procedure ........................................... 74

Coolant Temperature Switch - Remove andInstall ................................................................... 82Installation Procedure (402C-05, and 403C-07Engines) ........................................................... 84Installation Procedure (403C-11, 403C-15,403C-17, 404C-15, 404C-22, and 404C-22TEngines) ........................................................... 83Removal Procedure (402C-05, and 403C-07Engines) ........................................................... 83Removal Procedure (403C-11, 403C-15, 403C-17,404C-15, 404C-22, and 404C-22T Engines) ... 82

Crankcase Breather - Remove and Install............. 51Installation Procedure (Naturally AspiratedEngines) ........................................................... 52Installation Procedure (TurbochargedEngines) ........................................................... 53Removal Procedure (Naturally AspiratedEngines) ........................................................... 51Removal Procedure (Turbocharged Engines) ... 51

Crankshaft - Install................................................. 80Installation Procedure ........................................ 80

Crankshaft - Remove............................................. 78Removal Procedure ........................................... 78

Crankshaft Front Seal - Install ............................... 43Installation Procedure ........................................ 43

Crankshaft Front Seal - Remove........................... 43Removal Procedure ........................................... 43

Crankshaft Main Bearings - Install......................... 77Installation Procedure ........................................ 77

Crankshaft Main Bearings - Remove..................... 76Removal Procedure ........................................... 76

Crankshaft Pulley - Remove and Install ................ 42Installation Procedure ........................................ 42Removal Procedure ........................................... 42

Crankshaft Rear Seal - Install................................ 37Installation Procedure ........................................ 37

Crankshaft Rear Seal - Remove............................ 37Removal Procedure ........................................... 37

Cylinder Head - Install ........................................... 61Installation Procedure ........................................ 61

Cylinder Head - Remove ....................................... 60Removal Procedure ........................................... 60

D

Disassembly and Assembly Section........................ 4

E

Electric Starting Motor - Remove and Install ....... 101Installation Procedure ...................................... 102Removal Procedure ......................................... 101

Engine Oil Cooler - Remove and Install ................ 23Installation Procedure ........................................ 23Removal Procedure ........................................... 23

Engine Oil Line - Remove and Install .................... 21Installation Procedure ........................................ 22Removal Procedure ........................................... 21

Engine Oil Pan - Remove and Install..................... 67Installation Procedure ........................................ 68Removal Procedure ........................................... 67

Engine Oil Pressure Switch - Remove and Install.. 84Installation Procedure ........................................ 85Removal Procedure ........................................... 84

Engine Oil Pump - Install ....................................... 26Installation Procedure ........................................ 26

Engine Oil Pump - Remove................................... 24Removal Procedure ........................................... 24

Engine Oil Relief Valve - Remove and Install ........ 24Installation Procedure ........................................ 24Removal Procedure ........................................... 24

Exhaust Manifold - Remove and Install ................. 15Installation Procedure ........................................ 16Removal Procedure ........................................... 15


104 SENR9973-01Index Section

F

Fan - Remove and Install ...................................... 87Installation Procedure (402C-05, 403C-07,403C-11, 403C-15, 403C-17 and 404C-15Engines) ........................................................... 91Installation Procedure (404C-22 and 404C-22TEngines) ........................................................... 90Removal Procedure (402C-05, 403C-07, 403C-11,403C-15, 403C-17 and 404C-15 Engines)....... 88Removal Procedure (404C-22 and 404C-22TEngines) ........................................................... 87

Flywheel - Install.................................................... 36Installation Procedure ........................................ 36

Flywheel - Remove................................................ 35Removal Procedure ........................................... 35

Flywheel Housing - Remove and Install ................ 39Installation Procedure (Engines with FlywheelHousing and Back plate) .................................. 40Installation Procedure (Engines with FlywheelHousing)........................................................... 41Removal Procedure (Engines with FlywheelHousing and Back plate) .................................. 39Removal Procedure (Engines with FlywheelHousing)........................................................... 40

Fuel Filter Base - Install........................................... 6Installation Procedure .......................................... 6

Fuel Filter Base - Remove....................................... 5Removal Procedure ............................................. 5

Fuel Injection Lines - Remove and Install................ 7Installation Procedure .......................................... 8Removal Procedure ............................................. 7

Fuel Injection Pump - Install ................................... 11Installation Procedure ......................................... 11

Fuel Injection Pump - Remove .............................. 10Removal Procedure ........................................... 10

Fuel Injector - Install .............................................. 12Installation Procedure ........................................ 12

Fuel Injector - Remove .......................................... 12Removal Procedure ........................................... 12

Fuel Priming Pump - Install ..................................... 4Installation Procedure .......................................... 4

Fuel Priming Pump - Remove ................................. 4Removal Procedure ............................................. 4

Fuel Shutoff Solenoid - Remove and Install ............ 9Installation Procedure .......................................... 9Removal Procedure ............................................. 9

G

Glow Plugs - Remove and Install .......................... 86Installation Procedure ........................................ 86Removal Procedure ........................................... 86

H

Housing (Front) - Assemble................................... 47Assembly Procedure.......................................... 47

Housing (Front) - Disassemble.............................. 45Disassembly Procedure ..................................... 45

Housing (Front) - Install ......................................... 50Installation Procedure ........................................ 50

Housing (Front) - Remove..................................... 44Removal Procedure ........................................... 44

I

Important Safety Information ................................... 2Inlet and Exhaust Valve Springs - Remove andInstall ................................................................... 17Installation Procedure ........................................ 18Removal Procedure ........................................... 17

Inlet and Exhaust Valves - Remove and Install ..... 19Installation Procedure ........................................ 20Removal Procedure ........................................... 19

L

Lifter Group - Remove and Install.......................... 63Installation Procedure ........................................ 64Removal Procedure ........................................... 63

P

Pistons and Connecting Rods - Assemble ............ 71Assembly Procedure.......................................... 71

Pistons and Connecting Rods - Disassemble ....... 69Disassembly Procedure ..................................... 69

Pistons and Connecting Rods - Install................... 73Installation Procedure ........................................ 73

Pistons and Connecting Rods - Remove............... 68Removal Procedure ........................................... 68

R

Rocker Shaft - Assemble....................................... 57Assembly Procedure (402C-05, 403C-07, 403C-11and 404C-15 engines)...................................... 57Assembly Procedure (403C-15, 403C-17, 404C-22and 404C-22T engines) ................................... 58

Rocker Shaft - Disassemble .................................. 56Disassembly Procedure (402C-05, 403C-07,403C-11 and 404C-15 engines) ....................... 56Disassembly Procedure (403C-15, 403C-17,404C-22 and 404C-22T engines)..................... 56

Rocker Shaft and Pushrod - Install........................ 59Installation Procedure ........................................ 59

Rocker Shaft and Pushrod - Remove.................... 55Removal Procedure ........................................... 55

T

Table of Contents..................................................... 3



Turbocharger - Remove and Install ....................... 13Installation procedure......................................... 14Removal procedure............................................ 13

V

V-Belts - Remove and Install ................................. 86Installation Procedure ........................................ 87Removal Procedure ........................................... 86

Valve Mechanism Cover - Remove and Install ...... 54Installation Procedure ........................................ 54Removal Procedure ........................................... 54

W

Water Pump - Install .............................................. 30Installation Procedure (402C-05 and 403C-07Engines) ........................................................... 31Installation Procedure (403C-11, 403C-15,403C-17, 404C-15, 404C-22 and 404C-22TEngines) ........................................................... 30

Water Pump - Remove .......................................... 28Removal Procedure (402C-05 and 403C-07Engines) ........................................................... 29Removal Procedure (403C-11, 403C-15, 403C-17,404C-15, 404C-22 and 404C-22T Engines) .... 28

Water Temperature Regulator - Remove andInstall ................................................................... 32Installation Procedure (402C-05 and 403C-07engines) ........................................................... 34Installation Procedure (403C-11, 403C-15,403C-17, 404C-15, 404C-22 and 404C-22Tengines) ........................................................... 34Removal Procedure (402C-05 and 403C-07engines) ........................................................... 32Removal Procedure (403C-11, 403C-15, 403C-17,404C-15, 404C-22 and 404C-22T engines)..... 33

Water Temperature Regulator Housing - Remove andInstall ................................................................... 31Installation Procedure ........................................ 32Removal Procedure ........................................... 31


106 SENR9973-01Index Section


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