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詳細描述
Disassembly and
Assembly
2206-E13 Industrial Engine
Engine Oil Pump - Remove
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01385694
Illustration 66
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change”.
g01385651
Illustration 67
4. Remove bolts (7) and disconnect tube assembly
(5) from engine oil pump (11). Remove O-ring seal
(8) (not shown) from tube assembly (5).
5. Remove bolts (9) and disconnect tube assembly
(6) from engine oil pump (11).
6. Remove bolts (10).
7. Remove bolts (12).
8. Remove engine oil pump (11).
g01385650
Illustration 65
2. Loosen the hose clamps and disconnect hose (4)
from connection (2).
3. Remove bolts (1). Remove connection (2) from
the water pump. Remove O-ring seal (3) (not
shown) from the water pump.
g01386064
Illustration 68
This document has been printed from SPI². Not for Resale
KENR6906
33
Disassembly and Assembly Section
9. Remove O-ring seals (13) and (14) from engine
oil pump (11).
g01391548
Illustration 69
10. Remove O-ring seals (15) and (16) from engine
oil pump (11).
g01395753
Illustration 70
i02754790
1. Remove manifold (4).
Engine Oil Pump - Disassemble
2. Remove tube assemblies (5) and (9).
3. Remove the O-ring seals from tube assemblies
(5) and (9).
Disassembly Procedure
4. Use Tooling (A) in order to remove gear (2).
5. Remove bolts (10).
Table 15
Required Tools
Part
6. Remove cover (6) from engine oil pump (1).
Tool
Number
Part Description
Qty
A
-
Puller
1
7. Remove shaft assembly (3) and shaft assembly
(8) from engine oil pump (1).
Start By:
8. Remove oil seal (7).
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove”.
i02754791
Engine Oil Pump - Assemble
Assembly Procedure
Table 16
Required Tools
Tool
Part Number
Part Description
Qty
POWERPART
Rubber Grease
A
21820221
1
1. Ensure that all components of the engine oil pump
are clean and free from wear or damage. Refer
to the Specifications, “Engine Oil Pump” for more
information.
This document has been printed from SPI². Not for Resale
34
KENR6906
Disassembly and Assembly Section
8. Install new O-ring seals to tube assemblies (5) and
(9). Lubricate the O-ring seals with Tooling (A).
9. Install tube assemblies (5) and (9) to cover (6).
10. Install manifold (4) onto tube assemblies (5) and
(9).
End By:
a. Install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”.
i02754792
Engine Oil Pump - Install
Installation Procedure
g01395753
Illustration 71
Table 17
Required Tools
Tool
Part Number
Part Description
Qty
POWERPART
Rubber Grease
A
218200221
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01146945
Illustration 72
2. Lubricate shaft assemblies (3) and (8) with clean
engine oil. Install the shaft assemblies into engine
oil pump (1).
3. Install a new oil seal (7) to engine oil pump (1).
4. Position cover (6) onto engine oil pump (1) and
install bolts (10).
5. Tighten bolts (10) to a torque of 28 N·m (21 lb ft).
g01391548
Illustration 73
Always wear protective gloves when handling
parts that have been heated.
6. Heat gear (2) to a temperature of 316 °C (600 °F).
7. Install gear (2) to shaft assembly (3). Ensure
that Dimension (X) is 29.40 ± 0.50 mm
(1.158 ± 0.020 inch).
This document has been printed from SPI². Not for Resale
KENR6906
35
Disassembly and Assembly Section
6. Install new O-ring seal (8) (not shown) to tube
assembly (5). Connect the tube assembly to
engine oil pump (11) and install bolts (7).
7. Tighten bolts (7) and bolt (9) to a torque of 28 N·m
(21 lb ft).
g01386064
Illustration 74
1. Install new O-ring seal (14) to engine oil pump
(11). Lubricate the O-ring seal with Tooling (A).
2. Install new O-ring seals (13), (15) and (16) to
engine oil pump (11).
g01385650
Illustration 77
8. Install a new O-ring seal (3) (not shown) to the
water pump. position connection (2) and install
bolts (1). Tighten the bolts to a torque of 28 N·m
(21 lb ft).
9. Connect hose (4) to connection (2). Tighten the
hose clamps securely.
10. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.
i02754793
g01385651
Illustration 75
Water Pump - Remove
Removal Procedure
Start By:
a. Remove the front plate and the support bracket.
Refer to Disassembly and Assembly, “Front Plate
- Remove”
NOTICE
Keep all parts clean from contaminants.
g01385694
Illustration 76
Contaminants may cause rapid wear and shortened
component life.
3. Position engine oil pump (11) and install bolts (12)
finger tight.
4. Install bolts (10). Tighten bolts (10) and (12) to a
torque of 28 N·m (21 lb ft).
5. Connect tube assembly (6) to engine oil pump
(11) and install bolts (9).
This document has been printed from SPI². Not for Resale
36
KENR6906
Disassembly and Assembly Section
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change”.
g01384522
Illustration 79
4. Loosen the hose clamps and disconnect hose (9).
g01391599
Illustration 78
5. Remove bolts (11) and remove connection (10).
Remove O-ring seal (4) (not shown) from water
pump (12).
2. Remove bolts (1). Remove water temperature
regulator housing (2) as a unit. Remove the O-ring
seal from the water temperature regulator housing.
6. Loosen the hose clamps and slide hose (5) toward
connection (6). Remove bolts (7) and remove the
connection from water pump (12). Remove the
O-ring seal from the connection.
3. Remove tube assembly (3). Remove the O-ring
seals from the tube assembly.
7. Remove bolts (8).
8. Remove water pump (12).
g01391623
Illustration 80
This document has been printed from SPI². Not for Resale
KENR6906
37
Disassembly and Assembly Section
9. Remove O-ring seal (13) from water pump (12).
i02754794
Water Pump - Install
Installation Procedure
Table 18
Required Tools
Tool
Part Number
Part Description
Qty
POWERPART
Rubber Grease
A
218200221
1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that all mating surfaces are clean and free
from damage.
g01384522
Illustration 82
3. Position water pump (12) on the engine and install
bolts (8). Tighten the bolts to a torque of 55 N·m
(41 lb ft).
4. Install a new O-ring seal to connection (6). Loosely
assemble hose (5) and the hose clamps to the
connection.
5. Position connection (6) on water pump (12) and
install bolts (7). Tighten the bolts to a torque of
28 N·m (21 lb ft).
6. Connect hose (5) to the oil cooler. Tighten the
hose clamps securely.
g01391623
Illustration 81
2. Install a new O-ring seal (13) to water pump (12).
Lubricate the O-ring seal with Tooling (A).
7. Install a new O-ring seal (4) (not shown) to water
pump (12). Position connection (10) on the water
pump and install bolts (11). Tighten the bolts to a
torque of 28 N·m (21 lb ft).
8. Connect hose (9) and tighten the hose clamps
securely.
This document has been printed from SPI². Not for Resale
38
KENR6906
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant - Change”.
g01391599
Illustration 83
9. Install new O-ring seals to tube assembly (3).
Lubricate the O-ring seals with Tooling (A).
10. Install tube assembly (3) to the water pump.
11. Install a new O-ring seal to water temperature
regulator housing (2). Align the water temperature
regulator housing with tube assembly (3) and
install the water temperature regulator housing.
12. Install bolts (1). Tighten the bolts to a torque of
Illustration 84
g01390192
28 N·m (21 lb ft).
Typical example
13. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.
2. Remove bolts (1).
3. Remove water temperature regulator housing (2)
and tube assembly (3).
End By:
4. Remove the O-ring seals from tube assembly (3).
a. Install the front plate and the support bracket.
Refer to Disassembly and Assembly, “Front Plate
- Install”.
i02754796
Water Temperature Regulator
Housing - Remove and Install
Removal Procedure
NOTICE
g01390160
Illustration 85
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
5. Remove O-ring seal (7) from water temperature
regulator housing (2).
6. Remove water temperature regulator (6).
7. If necessary, remove lip seal (5) from water
temperature regulator housing (2).
Dispose of all fluids according to local regulations and
mandates.
This document has been printed from SPI². Not for Resale
KENR6906
39
Disassembly and Assembly Section
3. Ensure that valve (9) is clean and free from
restriction. If necessary, follow Steps 3.a and 3.b
in order to install the valve to housing manifold (8).
a. Install a new O-ring seal to valve (9). Apply
Tooling (B) to the O-ring seal.
b. Install valve (9) to housing manifold (8).
g01390109
Illustration 86
8. If necessary, remove valve (9) from housing
manifold (8). Remove the O-ring seal from the
valve.
Installation Procedure
g01390160
Illustration 88
Table 19
Required Tools
4. If necessary, install a new lip seal (5) to water
temperature regulator housing (2). Use Tooling
(A) to install the lip seal.
Tool
Part Number
Part Description
Qty
A
27610309
Seal Installer
1
5. Install a new O-ring seal (7) to water temperature
regulator housing (2).
POWERPART
Rubber Grease
B
21820221
1
6. Install water temperature regulator (6) to water
temperature regulator housing (2).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the mating surfaces of the water
temperature regulator housing and the housing
manifold are clean and free from damage.
2. Check the water temperature regulator for correct
operation. Refer to Systems Operation, Testing
and Adjusting, “Water Temperature Regulator -
Test” for the correct procedure.
g01390192
Illustration 89
Typical example
7. Install new O-ring seals to tube assembly (3).
Apply Tooling (B) to the O-ring seals. Install the
tube assembly to the water pump.
8. Position water temperature regulator housing (2)
and install bolts (1). Tighten the bolts to a torque
of 28 N·m (21 lb ft).
9. Fill the cooling system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
- Change”.
g01390109
Illustration 87
This document has been printed from SPI². Not for Resale
40
KENR6906
Disassembly and Assembly Section
i02754798
Installation Procedure
Engine Support (Front) -
Remove and Install
Table 21
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
(M12 by 100mm)
A
-
2
Removal Procedure
Table 20
1. Ensure that the front of the engine is supported.
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
(M12 by 100mm)
A
-
2
Start By:
a. Remove the vibration damper and the crankshaft
pulley. Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
1. Support the front of the engine.
g01380895
Illustration 91
2. Install Tooling (A) to positions (X) on the cylinder
block.
3. Install a suitable lifting device to engine
support (2). The weight of engine support (2) is
approximately 25 kg (55 lb).
4. Use the lifting device to align engine support (2)
with Tooling (A). Install the engine support to the
cylinder block.
5. Install bolts (1) finger tight. Remove Tooling (A)
and install the remaining bolts. Tighten bolts to a
torque of 100 N·m (74 lb ft).
g01380895
Illustration 90
2. Attach a suitable lifting device to engine
support (2). The weight of the engine support is
approximately 25 kg (55 lb).
End By:
a. Install the vibration damper and the crankshaft
pulley. Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
3. Remove bolts (1) from positions (X) and install
Tooling (A) to positions (X). Remove the remaining
bolts (1).
4. Use the lifting device to remove engine support
(2) from the cylinder block.
5. Remove Tooling (A).
This document has been printed from SPI². Not for Resale
KENR6906
41
Disassembly and Assembly Section
i02754801
5. Remove the remaining bolts (1). Use the lifting
device in order to remove flywheel (2).
Flywheel - Remove
Removal Procedure
Table 22
Required Tools
Part
Tool
Number
Part Description
Qty
Guide Stud
M16 by 120mm
A
-
2
Start By:
g01389418
Illustration 93
Typical example
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
6. Inspect flywheel (2) and ring gear (3) for wear or
damage. Replace any components that are worn
or damaged.
NOTICE
Keep all parts clean from contaminants.
7. To remove the ring gear, follow Steps 7.a and 7.b.
a. Place flywheel (2) on a suitable support.
Contaminants may cause rapid wear and shortened
component life.
Note: Identify the orientation of the teeth on the ring
gear.
b. Use a hammer and a punch in order to remove
ring gear (3) from flywheel (2).
i02754802
Flywheel - Install
Installation Procedure
Table 23
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
M16 by 120mm
A
-
2
g01383279
POWERPART
Threadlock and Nutlock
Illustration 92
B
21820117
1
Typical example
1. Attach a suitable lifting device to flywheel (2).
Support the weight of the flywheel. The weight of
the flywheel is approximately 50 kg (110 lb).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
2. Use a suitable tool to lock flywheel (2). Loosen
bolts (1).
3. Remove two bolts (1) from positions (X).
4. Install Tooling (A) to positions (X).
This document has been printed from SPI². Not for Resale
42
KENR6906
Disassembly and Assembly Section
g01389418
Illustration 94
Always wear protective gloves when handling
parts that have been heated.
g01389447
Illustration 95
1. If the ring gear was removed, follow Steps 1.a
through 1.c in order to install a new ring gear to
the flywheel.
Typical example
3. Install Tooling (A) to positions (X) on the
crankshaft.
a. Identify the orientation of the teeth on new ring
gear (3).
4. Install a suitable lifting device to flywheel (2). The
weight of the flywheel is approximately 50 kg
(110 lb).
Note: The chamfered side of the ring gear teeth must
face toward the starting motor when the flywheel is
installed. This will ensure the correct engagement of
the starting motor.
5. Use the lifting device in order to position flywheel
(2) onto Tooling (A). Ensure that Marks (Y) on the
flywheel and on the crankshaft are aligned.
b. Heat ring gear (3) in an oven to a maximum
temperature of 316 °C (600 °F) prior to
installation.
6. Apply Tooling (B) to the threads of bolts (1).
7. Install bolts (1). Remove Tooling (A). Install
remaining bolts (1).
Note: Do not use a torch to heat the ring gear.
8. Use a suitable tool to prevent the flywheel from
rotating. Tighten bolts (1) to a torque of 300 N·m
(221 lb ft).
c. Ensure that the orientation of ring gear (3) is
correct and quickly install the ring gear onto
flywheel (2).
9. Remove the lifting device from flywheel (2).
2. Inspect the crankshaft rear seal for leaks. If there
are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Rear Seal - Remove”.
10. Check the runout of the flywheel. Refer to
Systems Operations, Testing and Adjusting,
“Flywheel - Inspect”.
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
This document has been printed from SPI². Not for Resale
KENR6906
43
Disassembly and Assembly Section
i02754803
i02754805
Crankshaft Rear Seal - Remove
Crankshaft Rear Seal - Install
Removal Procedure
Installation Procedure
Start By:
Table 24
Required Tools
Part
a. Remove the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Remove”.
Tool
Number
Part Description
Qty
POWERPART
Threadlock and Nutlock
NOTICE
Keep all parts clean from contaminants.
A
21820117
1
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the crankshaft flange and the housing
for the crankshaft rear seal is clean, dry and free
from damage. It is possible to reclaim a crankshaft
flange that has a worn seal surface, or a damaged
seal surface by installing a wear sleeve. Refer to
Disassembly and Assembly, “Crankshaft Wear
Sleeve (Rear) - Remove and Install” for more
information.
g01389635
Illustration 96
1. Remove bolts (1) and (3).
2. Remove crankshaft rear seal (2).
3. Remove the O-ring seal from crankshaft rear seal
(2).
g01389636
Illustration 97
This document has been printed from SPI². Not for Resale
44
KENR6906
Disassembly and Assembly Section
i02807660
Crankshaft Wear Sleeve (Rear)
- Remove and Install
Removal Procedure
Start By:
a. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.
g01395750
Illustration 98
Tightening sequence for the crankshaft rear seal
NOTICE
Keep all parts clean from contaminants.
2. Install a new O-ring seal to crankshaft rear seal
(2). A new crankshaft rear seal is supplied with a
plastic sleeve. Ensure that the plastic sleeve is
squarely installed within the crankshaft rear seal.
Contaminants may cause rapid wear and shortened
component life.
Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
are not original equipment.
Note: The plastic sleeve is included in order to
protect the lip of the seal as the seal is pushed over
the crankshaft flange.
1. Use a sharp tool to score a deep line across the
crankshaft wear sleeve.
Note: Do not lubricate the crankshaft rear seal or
the crankshaft flange. The crankshaft rear seal
must be installed dry.
Note: Take care to avoid damaging the crankshaft.
3. Align the plastic sleeve with the crankshaft flange.
Ensure that the plastic sleeve is engaged onto the
crankshaft flange. Push new crankshaft rear seal
(2) squarely onto the crankshaft flange.
2. Insert a thin blade between the crankshaft wear
sleeve and the crankshaft below the scored line.
The crankshaft wear sleeve will separate along
the line.
During this process, the plastic sleeve will be
forced out of the crankshaft rear seal. Discard the
plastic sleeve.
3. Remove the crankshaft wear sleeve from the
crankshaft.
Installation Procedure
4. Apply Tooling (A) to the threads of bolts (3). Install
bolts (1) and (3). Tighten the bolts to a torque of
12 N·m (105 lb in) in the numerical sequence that
is shown in Illustration 98.
Table 25
Required Tools
Tool
Part Number
21820518
CVT0017
-
Part Description
Qty
1
End By:
POWERPART
Liquid Gasket
A
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
Installer
1
B
Bolt
(M16 by 30 mm)
3
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
KENR6906
45
Disassembly and Assembly Section
Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
are not original equipment.
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
1. Ensure that the crankshaft is thoroughly clean and
dry. Remove any areas of raised damage.
b. Remove the flywheel. Refer to Disassembly and
2. Apply a small continuous bead of Tooling (A) to the
inner surface of the crankshaft wear sleeve. Apply
the bead of Tooling (A) 5.00 mm (0.2 inch) from
the chamfered end of the crankshaft wear sleeve.
Assembly, “Flywheel - Remove”.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01401603
Illustration 99
Sectional view of the crankshaft, the wear sleeve and the
installation tool
1. Support the rear of the engine.
3. Align crankshaft wear sleeve (1) with crankshaft
(2). Install Tooling (B) to crankshaft (2). Evenly
tighten the bolts of Tooling (B) in order to install
the crankshaft wear sleeve.
4. Remove Tooling (B).
End By:
a. Install a new crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear
Seal - Install”.
i02754806
Flywheel Housing - Remove
and Install
g01383281
Illustration 100
Removal Procedure
2. Attach a suitable lifting device to flywheel
housing (2). The weight of the flywheel housing is
approximately 25 kg (55 lb).
Table 26
Required Tools
Tool
Part Number
Part Description
Qty
3. Remove bolts (1) from positions (X). Install Tooling
(A) to positions (X).
Guide Stud
(M14 by 100mm)
A
-
2
4. Remove the remaining bolts (1). Use the lifting
device to remove flywheel housing (2) from the
cylinder block.
This document has been printed from SPI². Not for Resale
46
KENR6906
Disassembly and Assembly Section
Note: It is not necessary to remove the dowels in the
cylinder block that locate the flywheel housing.
g01389649
Illustration 101
5. Remove O-ring seal (3) from housing (4).
Installation Procedure
g01383281
Illustration 103
Table 27
3. Apply Tooling (B) to the rear face of the cylinder
block.
Required Tools
Part
Note: The flywheel housing must be installed within
ten minutes of applying Tooling (B).
Tool
Part Description
Qty
Number
Guide Stud
(M14 by 100mm)
A
B
-
2
1
4. Install Tooling (A) to positions (X) in the cylinder
block.
CH10879
Sealant
5. Attach a suitable lifting device to flywheel
housing (2). The weight of the flywheel housing is
approximately 25 kg (55 lb).
1. Ensure that the mating surfaces of the flywheel
housing and the cylinder block are clean and free
from damage.
6. Use the lifting device to align flywheel housing (2)
with Tooling (A).
7. Install flywheel housing (2) to the cylinder block.
8. Install bolts (1). Remove Tooling (A). Install the
remaining bolts. Tighten the bolts to a torque of
160 N·m (118 lb ft).
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, “Flywheel - Install”.
b. Install the electric starting motor. Refer to
Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
g01389649
Illustration 102
2. Install a new O-ring seal (3) to housing (4).
This document has been printed from SPI². Not for Resale
KENR6906
47
Disassembly and Assembly Section
i02754807
Vibration Damper and Pulley -
Remove and Install
Removal Procedure
Table 28
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
(M16 by 120mm)
A
-
2
g01380897
Illustration 105
2. Remove the V-belts from crankshaft pulley (4).
Temporarily secure the V-belts in a position that
is clear of vibration damper (3).
Start By:
a. Remove the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”.
3. Remove two bolts (6). Install Tooling (A).
4. Remove the remaining bolts (6) and spacer (5).
5. Remove crankshaft pulley (4).
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
6. Install a suitable lifting device to vibration damper
(3). The weight of the vibration damper is
approximately 36 kg (79 lb). Make a temporary
mark in order to show the front of the vibration
damper for installation.
7. Use the lifting device to remove vibration damper
(3) from the crankshaft.
8. Remove Tooling (A) from the crankshaft.
Installation Procedure
Table 29
Required Tools
Tool
Part Number
Part Description
Qty
Guide Stud
A
-
2
(M16 by 120mm)
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Thoroughly inspect the viscous damper for signs of
leakage or for signs of a dented (damaged) case.
Either of these conditions can cause the weight to
make contact with the case. This can affect the vis-
cous damper’s operation.
g01417120
Illustration 104
1. Loosen nut (1) that locks the position of the belt
tightener. Rotate bolt (2) in order to release the
tension on the V-belts.
This document has been printed from SPI². Not for Resale
48
KENR6906
Disassembly and Assembly Section
1. Inspect the components for damage. Replace any
components that are damaged.
2. Inspect the crankshaft front seal for leaks. If
necessary, replace the crankshaft front seal. Refer
to Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
3. Install Tooling (A) to the crankshaft.
g01380897
Illustration 106
4. Install a suitable lifting device to vibration damper
(3). The weight of the vibration damper is
approximately 36 kg (79 lb).
g01417120
Illustration 107
5. Use the lifting device to align vibration damper (3)
with Tooling (A). Install the vibration damper to the
crankshaft.
9. Position the V-belts on the crankshaft pulley and
the pulley of the belt tightener.
10. Rotate bolt (2) in order to adjust the tension of
the V-belts. Refer to Operation and Maintenance
Manual, “Belts - Inspect/Adjust/Replace”.
Note: Ensure correct orientation of the vibration
damper.
6. Remove the lifting device.
11. Tighten nut (1) in order to lock the position of the
belt tightener.
7. Install crankshaft pulley (4) and spacer (5).
End By:
8. Install bolts (6). Remove Tooling (A) and install the
remaining bolts (6). Tighten the bolts to a torque
of 240 N·m (177 lb ft).
a. Install the fan. Refer to Disassembly and
Assembly, “Fan - Remove and Install”.
i02754808
Crankshaft Front Seal -
Remove
Removal Procedure
Start By:
a. Remove the vibration damper and the crankshaft
pulley. Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
This document has been printed from SPI². Not for Resale
KENR6906
49
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01383288
Illustration 109
g01383288
Illustration 108
1. Remove nuts (1).
2. Remove crankshaft front seal (2).
3. Remove the O-ring seal from crankshaft front seal
(2).
g01132632
Illustration 110
i02754809
Tightening sequence for the crankshaft front seal
Crankshaft Front Seal - Install
,2. Install a new O-ring seal to crankshaft front seal
(2). A new crankshaft front seal is supplied with a
plastic sleeve. Ensure that the plastic sleeve is
squarely installed within the crankshaft front seal.
Installation Procedure
Note: The plastic sleeve is included in order to
protect the lip of the seal as the seal is pushed over
the crankshaft flange.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Do not lubricate the crankshaft front seal or
the crankshaft flange. The crankshaft front seal
must be installed dry.
1. Ensure that the crankshaft flange and the front
cover are clean, dry and free from damage.
3. Align the plastic sleeve with the crankshaft flange.
Ensure that the plastic sleeve is engaged onto the
crankshaft flange. Push new crankshaft front seal
(2) squarely onto the crankshaft flange.
During this process, the plastic sleeve will be
forced out of the crankshaft front seal. Discard the
plastic sleeve.
4. Install nuts (1). Tighten the nuts to a torque of
12 N·m (105 lb in) in the numerical sequence that
is shown in Illustration 110.
This document has been printed from SPI². Not for Resale
50
KENR6906
Disassembly and Assembly Section
End By:
Installation Procedure
a. Install the vibration damper and the crankshaft
pulley. Refer to Disassembly and Assembly,
“Vibration Damper and Pulley - Remove and
Install”.
Table 31
Required Tools
Tool
Part Number
21820518
CVT0018
-
Part Description
Qty
1
POWERPART
Liquid Gasket
A
i02810672
Installer
1
Crankshaft Wear Sleeve (Front)
- Remove and Install
B
Bolt
(M16 by 30 mm)
3
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
Contaminants may cause rapid wear and shortened
component life.
Table 30
Required Tools
Part
Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
are not original equipment.
Tool
Number
Part Description
Qty
A
-
Puller
1
1. Ensure that the crankshaft is thoroughly clean and
dry. Remove any areas of raised damage.
Start By:
a. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
2. Apply a small continuous bead of Tooling (A) to the
inner surface of the crankshaft wear sleeve. Apply
the bead of Tooling (A) 5.00 mm (0.2 inch) from
the chamfered end of the crankshaft wear sleeve.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
are not original equipment.
1. Use a sharp tool to score a deep line across the
crankshaft wear sleeve.
Note: Take care to avoid damaging the crankshaft.
g01402019
Illustration 111
2. Insert a thin blade between the crankshaft wear
sleeve and the crankshaft below the scored line.
The crankshaft wear sleeve will separate along
the line.
Sectional view of the crankshaft, the wear sleeve and the
installation tool
3. Align crankshaft wear sleeve (1) with crankshaft
(2). Install Tooling (B) to crankshaft (2). Evenly
tighten the bolts of Tooling (B) in order to install
the crankshaft wear sleeve.
3. Remove the crankshaft wear sleeve from the
crankshaft.
4. Remove Tooling (B).
This document has been printed from SPI². Not for Resale
KENR6906
51
Disassembly and Assembly Section
End By:
a. Install a new crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Install”.
i02754810
Front Cover - Remove
Removal Procedure
g01392333
Start By:
Illustration 113
Typical example
a. Remove the front plate. Refer to Disassembly and
Assembly, “Front Plate - Remove”.
2. Remove bolts (3) and (4).
b. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01395833
Illustration 114
3. Remove bolts (5), fasteners (6) and bolt (7).
4. Remove front cover (8) and joint (9) (not shown).
i02754811
Front Cover - Install
Installation Procedure
Table 32
g01395819
Illustration 112
Required Tools
Part
1. Remove bolts (1) and plate (2). Remove the
O-ring seal from the front housing.
Tool
Number
Part Description
Qty
POWERPART
Threadlock and Nutlock
A
21820117
1
This document has been printed from SPI². Not for Resale
52
KENR6906
Disassembly and Assembly Section
5. Install bolts (3). Tighten the bolts to a torque of
55 N·m (41 lb ft).
NOTICE
Keep all parts clean from contaminants.
6. Apply Tooling (A) to bolt (7).
7. Install bolts (4), (5) and (7).
Contaminants may cause rapid wear and shortened
component life.
8. Tighten bolts (4), (5) and (7) to a torque of 28 N·m
(21 lb ft).
1. Ensure that the front cover and the mating surface
of the front housing are clean and free from
damage.
g01395819
Illustration 117
9. Install a new O-ring seal to the front housing.
Position plate (2) and install bolts (1). Tighten the
bolts to a torque of 55 N·m (41 lb ft).
End By:
a. Install a new crankshaft front seal. Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Install”.
g01395833
Illustration 115
b. Install the front plate. Refer to Disassembly and
Assembly, “Front Plate - Install”.
i02754812
Gear Group (Front) - Remove
Removal Procedure
Table 33
g01392333
Illustration 116
Required Tools
Part
Typical example
2. Align a new joint (9) (not shown) with the dowels
in the front housing. Install the joint.
Tool
Number
CH11148
27610286
CVT0015
Part Description
Crankshaft Turning Tool
Timing Pin (Crankshaft)
Adapter
Qty
1
A
3. Align front cover (8) with the dowels in the front
housing. Install the front cover.
1
B
1
4. Install fasteners (6). Tighten the fasteners to a
torque of 100 N·m (74 lb ft).
This document has been printed from SPI². Not for Resale
KENR6906
53
Disassembly and Assembly Section
Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove”.
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Use Tooling (A) in order to rotate the crankshaft so
that number one piston is at the top center position
on the compression stroke. Refer to Systems
Operation, Testing and Adjusting, “Finding Top
Centre Position for No.1 Piston”.
g01400788
Illustration 119
2. Install Tooling (B) to the flywheel housing. Use
Tooling (B) in order to align the flywheel in the
correct position. Refer to Systems Operation,
Testing and Adjusting, “Finding Top Centre
Position for No.1 Piston”.
4. Ensure that the timing marks on gears (3), (4) and
(5) are aligned.
g01400786
Illustration 120
g01393906
Illustration 118
5. Follow Step 5.a through Step 5.c in order to
remove idler gear (4).
3. Loosen nuts (1) on all rocker arms . Unscrew
adjusters (2) on all rocker arms until all valves are
fully closed.
a. Remove bolt (8).
b. Carefully use a pry bar in order to remove gear
(4) and hub (10).
Note: Failure to ensure that ALL adjusters are fully
unscrewed can result in contact between the valves
and pistons.
c. Remove hub (10) from gear (4).
6. Follow Step 6.a through Step 6.c in order to
remove idler gear (6).
a. Remove bolt (7).
b. Carefully use a pry bar in order to remove gear
(6) and hub (9).
c. Remove hub (9) from gear (6).
This document has been printed from SPI². Not for Resale
54
KENR6906
Disassembly and Assembly Section
i02754815
Gear Group (Front) - Install
Installation Procedure
Table 34
Required Tools
Part
Tool
Number
CH11148
27610286
CVT0015
Part Description
Crankshaft Turning Tool
Timing Pin (Crankshaft)
Adapter
Qty
1
A
1
B
1
NOTICE
Keep all parts clean from contaminants.
g01400788
Illustration 122
Contaminants may cause rapid wear and shortened
component life.
4. Follow Step 4.a through Step 4.c in order to install
idler gear (6).
1. Ensure that number one piston is at the top center
position on the compression stroke. Refer to
the Systems Operation, Testing and Adjusting,
“Finding Top Center Position for No. 1 Piston”.
a. Lubricate hub (9) with clean engine oil. Slide
the hub into idler gear (6). Ensure that the word
FRONT on the idler gear is toward the front.
b. Install the assembly of idler gear (6) and hub
(9) into the recess in the front housing. Ensure
that the oil hole in the hub is upward.
2. Ensure that Tooling (B) is installed in the flywheel
housing. Tooling (B) is used to align the flywheel in
the correct position. Refer to Systems Operation,
Testing and Adjusting, “Finding Top Centre
Position for No.1 Piston”.
Note: The idler gear must be tilted during installation.
c. Install bolt (7). Tighten the bolt to a torque of
240 N·m (177 lb ft).
3. Ensure that all of the components of the front gear
group are clean and free from wear or damage. If
necessary, replace any components that are worn
or damaged. Refer to Specifications, “Gear Group
(Front)” for more information.
5. Follow Step 5.a through Step 5.c in order to install
idler gear (4).
a. Lubricate hub (10) with clean engine oil. Slide
the hub into idler gear (4). Ensure that the word
FRONT on the idler gear is toward the front.
b. Align the timing marks on idler gear (4) with
the timing marks on camshaft gear (3) and the
timing marks on crankshaft gear (5). Refer to
the Illustration 122. Install the assembly of idler
gear (4) and hub (10) into the recess in the
front housing. Ensure that the oil hole in the
hub is upward.
c. Install bolt (8). Tighten the bolt to a torque of
460 N·m (340 lb ft).
g01400786
Illustration 121
6. Remove Tooling (B).
7. Lubricate each gear with clean engine oil.
This document has been printed from SPI². Not for Resale
KENR6906
55
Disassembly and Assembly Section
8. Adjust the engine valve lash. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust”.
9. Remove Tooling (A).
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Install”.
b. Install the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
i02754817
Housing (Front) - Remove
g01393936
Removal Procedure
Illustration 123
1. Remove bolts (1).
Start By:
2. Remove front housing (2).
3. Remove joint (4).
a. Remove the atmospheric pressure sensor. Refer
to Disassembly and Assembly, “Atmospheric
Pressure Sensor - Remove and Install”.
4. If necessary, remove pump drive (3) from front
housing (2). Refer to Disassembly and Assembly,
“Pump Drive- Remove”.
b. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
c. Remove the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
Sensor - Remove and Install”.
i02754818
Housing (Front) - Install
d. Remove the fuel transfer pump. Refer to
Disassembly and Assembly, “Fuel Transfer Pump
- Remove”.
Installation Procedure
e. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove”.
Table 35
Required Tools
Part
f. Remove the water pump. Refer to Disassembly
Tool
Number
Part Description
Qty
and Assembly, “Water Pump - Remove”.
Guide Stud
A
-
2
(M8 by 80 mm)
NOTICE
g. Remove the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Install”.
Keep all parts clean from contaminants.
h. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”.
Contaminants may cause rapid wear and shortened
component life.
i. Remove the front gear group. Refer to
Disassembly and Assembly, “Gear Group (Front)
- Remove”.
1. Clean the mating surfaces of the cylinder block
and the front housing.
j. Remove the front engine support. Refer to
Disassembly and Assembly, “Engine Support
(Front) - Remove and Install”.
This document has been printed from SPI². Not for Resale
56
KENR6906
Disassembly and Assembly Section
8. If necessary, install pump drive (3) to front housing
(2). Refer to Disassembly and Assembly, “Pump
Drive- Install”.
End By:
a. Install the front engine support. Refer to
Disassembly and Assembly, “Engine Support
(Front) - Remove and Install”.
b. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and
Install”.
c. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
d. Install the front gear group. Refer to Disassembly
and Assembly, “Gear Group (Front) - Install”.
e. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
g01393955
Illustration 124
f. Install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”.
2. Install Tooling (A) to the cylinder block.
g. Install the fuel transfer pump. Refer to Disassembly
and Assembly, “Fuel Transfer Pump - Install”
h. Install the crankshaft position sensor. Refer to
Disassembly and Assembly, “Crankshaft Position
Sensor - Remove and Install”.
i. Install the camshaft position sensor. Refer to
Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
j. Install the atmospheric pressure sensor. Refer
to Disassembly and Assembly, “Atmospheric
Pressure Sensor - Remove and Install”.
i02767682
Front Plate - Remove
g01393936
Illustration 125
Removal Procedure
3. Install a new joint (4) to the cylinder block.
4. Install front housing (2).
Start By:
Note: Ensure that the front housing is seated
correctly on the dowels in the cylinder block.
a. Remove the belt tightener. Refer to Disassembly
and Assembly, “Belt Tightener - Remove”.
5. Install bolts (1).
b. Remove the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Remove”.
6. Remove Tooling (A) and install the remaining bolts
(1).
7. Tighten bolts (1) to a torque of 28 N·m (21 lb ft).
This document has been printed from SPI². Not for Resale
KENR6906
57
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01397091
Illustration 128
6. If necessary, follow Steps 6.a and 6.b in order to
remove the support bracket.
a. Remove bolts (6).
g01386146
Illustration 126
b. Remove support bracket (7).
i02767679
Front Plate - Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01397095
Illustration 127
1. Remove bolts (3) (not shown) that secure plate (4)
to the support bracket.
2. Remove nuts (1).
3. Support the weight of plate (4). The weight of the
plate is approximately 25 kg (55 lb).
4. Remove nuts (2) and remove plate (4).
5. Remove spacer (5) from the cylinder head. Note
the routing of the wiring harness between the
spacer and the cylinder head.
g01397091
Illustration 129
1. If support bracket (7) was removed, position the
support bracket on the cylinder block and install
bolts (6) finger tight.
This document has been printed from SPI². Not for Resale
58
KENR6906
Disassembly and Assembly Section
b. Install the belt tightener. Refer to Disassembly and
Assembly, “Belt Tightener - Install”.
i02754819
Crankcase Breather - Remove
and Install
(Closed Breather)
Removal Procedure
g01397095
Illustration 130
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
g01386146
Illustration 131
2. Install spacer (5) to the cylinder head.
Note: Ensure the correct routing of the wiring harness
around the spacer.
3. Position plate (4) on the studs and install nuts (1)
and (2).
4. Tighten nuts (1) and (2) to a torque of 100 N·m
(74 lb ft).
5. Install bolts (3) (not shown) finger tight.
6. If support bracket (7) was removed, tighten bolts
(6) to a torque of 55 N·m (41 lb ft). Refer to
Illustration 129.
7. Tighten bolts (3) (not shown) to a torque of 55 N·m
(41 lb ft).
Note: Ensure that the plate is not stressed as the
bolts are tightened.
g01401970
Illustration 132
End By:
1. Loosen the clamp and disconnect hose (1) from
crankcase breather (4).
a. Install the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Install”.
2. Loosen the clamp and disconnect hose (3) from
crankcase breather (4).
This document has been printed from SPI². Not for Resale
KENR6906
59
Disassembly and Assembly Section
3. Disconnect hose (5) from crankcase breather (4).
i02790384
Crankcase Breather - Remove
and Install
4. Remove bolts (2) and remove crankcase breather
(4) from the mounting bracket.
(Open Breather)
5. If necessary, disassemble crankcase breather
(4). Refer to Operation and Maintenance Manual,
“Engine Crankcase Breather - Replace” for the
correct procedure.
Removal Procedure
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Contaminants may cause rapid wear and shortened
component life.
g01401675
Illustration 134
g01401970
Illustration 133
1. Remove bolt (2), clip (3) and spacer (4).
1. Ensure that hoses (1), (3) and (5) are clean and
free from restriction.
2. Loosen the hose clamp and remove hose (1) from
the valve mechanism cover base.
2. If necessary, assemble crankcase breather (4).
Refer to Operation and Maintenance Manual,
“Engine Crankcase Breather - Replace” for the
correct procedure.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
3. Position crankcase breather (4) on the mounting
bracket and install bolts (2). Tighten the bolts to a
torque of 28 N·m (21 lb ft).
Contaminants may cause rapid wear and shortened
component life.
4. Connect hose (5) to crankcase breather (4).
Tighten the nut securely.
5. Connect hose (3) to crankcase breather (4).
Tighten the clamp securely.
6. Connect hose (1) to crankcase breather (4).
Tighten the clamp securely.
This document has been printed from SPI². Not for Resale
60
KENR6906
Disassembly and Assembly Section
g01401675
g01380899
Illustration 135
Illustration 136
1. Ensure that hose (1) is clean and free from
damage.
2. Install hose (1) to the valve mechanism cover
base. Tighten the clamp securely.
3. Install bolt (2), clip (5) and spacer (4). Tighten the
bolt to a torque of 55 N·m (41 lb ft).
i02754820
Valve Mechanism Cover -
Remove and Install
g01380900
Illustration 137
Tightening sequence for the valve mechanism cover
Removal Procedure
1. Gradually loosen bolts (2) in reverse numerical
order to the sequence that is shown in Illustration
137. This will help prevent distortion of the valve
mechanism cover.
NOTICE
Keep all parts clean from contaminants.
2. Remove bolts (2) and isolators (3) from valve
mechanism cover (1).
Contaminants may cause rapid wear and shortened
component life.
3. Remove valve mechanism cover (1) from the
valve mechanism cover base.
4. Remove joint (4).
This document has been printed from SPI². Not for Resale
KENR6906
61
Disassembly and Assembly Section
Installation Procedure
i02754821
Valve Mechanism Cover Base -
Remove and Install
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01380899
Illustration 138
1. Install a new joint (4) to the valve mechanism
cover base.
Note: Ensure that the joint is correctly located on
the valve mechanism cover base with TOP, FRONT
upward.
2. Place valve mechanism cover (2) in position and
install isolators (3).
g01398095
Illustration 140
Typical example
1. Disconnect harness assembly (7) from valve
mechanism cover base (1).
2. Disconnect harness assembly (2) from electronic
unit injectors (3).
3. Disconnect hose (6) from separator (5).
4. Gradually loosen bolts (4). Loosen the outer bolts