Kenr6052 01 01 All PDF

KENR6052-01
November 2009
Disassembly and
Assembly
C175-16 and C175-20 Engines for
Caterpillar Built Machines
B7B1-Up (Engine)
B7C1-Up (Engine)
JTL1-Up (Engine)
LLM1-Up (Engine)
SAFETY.CAT.COM
i03684547
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR6052-01
Table of Contents
Disassembly and Assembly Section
Air Starting Motor - Remove ................................... 4
Air Starting Motor - Install ....................................... 4
Electronic Control Module (Engine) - Remove and
Install ..................................................................... 5
Fuel Filter Housing - Remove (Secondary) ............ 6
Fuel Filter Housing - Remove (Secondary) ............ 7
Fuel Filter Housing - Install ..................................... 7
Fuel Filter Housing - Install ..................................... 8
Fuel Priming Pump - Remove and Install .............. 9
Fuel Transfer Pump - Remove .............................. 10
Fuel Transfer Pump - Install .................................. 10
High Pressure Fuel Rails - Remove and Install ..... 11
Flow Limiter - Remove and Install ........................ 15
Fuel Control Valve - Remove and Install .............. 17
Fuel Pump (High Pressure) - Remove and Install .. 18
Turbocharger - Remove ........................................ 20
Turbocharger - Install ............................................ 22
Air Inlet Manifold - Remove and Install ................ 23
Exhaust Elbow - Remove and Install ................... 23
Exhaust Manifold - Remove and Install ............... 24
Water Pump - Remove ......................................... 26
Water Pump - Disassemble ................................. 26
Water Pump - Assemble ...................................... 28
Water Pump - Install ............................................. 31
Fuel and Auxiliary Water Pump Drive - Remove and
Install ................................................................... 32
Auxiliary Water Pump - Remove .......................... 35
Auxiliary Water Pump - Disassemble ................... 35
Auxiliary Water Pump - Assemble ....................... 37
Auxiliary Water Pump - Install .............................. 40
Engine Oil Cooler - Remove ................................. 41
Engine Oil Cooler - Disassemble ......................... 42
Engine Oil Cooler - Assemble .............................. 43
Engine Oil Cooler - Install ..................................... 43
Engine Oil Pump - Remove .................................. 44
Engine Oil Pump - Disassemble ........................... 47
Engine Oil Pump - Assemble ................................ 48
Engine Oil Pump - Install ...................................... 49
Engine Oil Filter Housing - Remove ..................... 51
Engine Oil Filter Housing - Install ......................... 52
Engine Oil and Water Pump Drive - Remove ....... 52
Engine Oil and Water Pump Drive - Disassemble .. 53
Engine Oil and Water Pump Drive - Assemble ..... 53
Engine Oil and Water Pump Drive - Install ........... 54
Engine Oil Screen - Remove and Install .............. 55
Engine Oil Pan - Remove .................................... 57
Engine Oil Pan - Disassemble .............................. 58
Engine Oil Pan - Assemble ................................... 59
Engine Oil Pan - Install ........................................ 59
Engine Oil Scavenge Pump - Remove ................. 61
Engine Oil Scavenge Pump - Disassemble .......... 62
Engine Oil Scavenge Pump - Assemble ............... 63
Engine Oil Scavenge Pump - Install ..................... 65
Crankcase Breather - Remove and Install ........... 66
Valve Cover - Remove and Install ........................ 67
Rocker Shaft and Push Rods - Remove .............. 68
Rocker Shaft - Disassemble ................................ 68
3
Table of Contents
Rocker Shaft - Assemble ..................................... 69

Rocker Shaft and Push Rods - Install .................. 69
Valve Lifter - Remove ........................................... 70
Valve Lifter - Disassemble .................................... 71
Valve Lifter - Assemble ......................................... 71
Valve Lifter - Install ............................................... 72
Electronic Unit Injector - Remove ......................... 72
Electronic Unit Injector - Install ............................. 74
Electronic Unit Injector Sleeve - Remove ............. 75
Electronic Unit Injector Sleeve - Install ................. 76
Cylinder Head - Remove ...................................... 77
Cylinder Head - Install .......................................... 78
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 80
Inlet and Exhaust Valves - Remove and Install .... 81
Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 83
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 84
Inlet Valve Seals - Remove and Install ................. 85
Front Drive Housing - Remove and Install ........... 87
Vibration Damper - Remove and Install ............... 89
Crankshaft Front Seal - Remove .......................... 91
Crankshaft Front Seal - Install .............................. 91
Flywheel - Remove and Install ............................. 92
Crankshaft Rear Seal - Remove ........................... 93
Crankshaft Rear Seal - Install ............................... 94
Flywheel Housing - Remove ................................. 95
Flywheel Housing - Install ..................................... 96
Idler Gears (Front) - Remove and Install .............. 98
Gear Group (Rear) - Remove ............................. 100
Gear Group (Rear) - Install ................................. 101
Piston Cooling Jets - Remove and Install ........... 102
Bearing Clearance - Check ................................. 103
Connecting Rod Bearings - Remove and Install
........................................................................... 104
Crankshaft Main Bearings - Remove .................. 106
Crankshaft Main Bearings - Install ...................... 108
Pistons, Liners, and Connecting Rods Remove .............................................................. 110
Pistons and Connecting Rods - Disassemble ...... 112
Pistons and Connecting Rods - Assemble .......... 113
Pistons, Liners, and Connecting Rods - Install .... 115
Camshaft - Remove ............................................. 116
Camshaft Bearings - Remove .............................. 118
Camshaft Bearings - Install .................................. 119
Camshaft - Install ................................................ 121
Crankshaft - Remove .......................................... 123
Crankshaft - Install .............................................. 125
Air Compressor - Remove and Install ................ 128
Engine Trunnion - Remove and Install ................ 129
Accessory Drive (Rear) - Remove ...................... 131
Accessory Drive (Rear) - Install .......................... 132
Index Section
Index ................................................................... 135
4
KENR6052-01
Disassembly and Assembly

Section
i02649756
Air Starting Motor - Remove

SMCS Code: 1451-011
Removal Procedure
Note: Cleanliness is an important factor. Before the
removal procedure, the exterior of the component
should be thoroughly cleaned. This will help to
prevent dirt from entering the internal mechanism.
Note: Put identification marks on all hoses for
installation purposes. Plug all hoses. This helps to
prevent fluid loss and this helps to keep contaminants
from entering the system.
1. Turn OFF air supply valve, and purge the air from
the hoses.
Illustration 2
g01330211
5. Attach a suitable lifting device to air starting

motor (4). The weight of air starting motor (4) is
approximately 29 kg (63 lb).
6. Remove bolts (5).
7. Remove air starting motor (4).
i02649858
Air Starting Motor - Install

SMCS Code: 1451-012
Installation Procedure
Note: Cleanliness is an important factor. Before the
installation procedure, the exterior of the component
should be thoroughly cleaned. This will help to
prevent dirt from entering the internal mechanism.
Illustration 1
g01330208
2. Disconnect hose assembly (1) from air starting

motor (4).
motor (4).
motor (4).
KENR6052-01
5
7. Turn ON air supply valve.

i02649946
Electronic Control Module

(Engine) - Remove and Install
SMCS Code: 1900-010
Removal Procedure
Illustration 3
g01330211
1. Attach a suitable lifting device to air starting

motor (4). The weight of air starting motor (4) is
2. Position air starting motor (4).
3. Install bolts (5).
Illustration 5
g01811974
1. Remove screws (4) and disconnect harness

assemblies (1) and (5). Remove bolts (2), the
mounts, the washers, and the spacers. Remove
electronic control module (3).
Illustration 4
g01330208
4. Connect hose assembly (3) to air starting motor

(4).
(4).
(4).
6
KENR6052-01
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Turn the fuel supply to the OFF position.
g01811974
Illustration 6
1. Position electronic control module (3). Install the

spacers, the washers, the mounts, and bolts (2).
Position harness assemblies (5) and (1). Install
screws (4). Tighten screws (4) to a torque of
6 1 Nm (53 9 lb in).
i02632312
Fuel Filter Housing - Remove

(Secondary)
SMCS Code: 1262-011
S/N: SSP; B7B1-Up
S/N: EMD; B7C1-Up
Illustration 7
S/N: ERM; JTL1-Up
g01818667
Note: Cap tube assemblies, fittings, ports, and any

openings on the fuel system in order to prevent
contamination.
Removal Procedure
Table 1
2. Use Tooling (A) to remove fuel filters (6).

Required Tools
Tool
Part Number
Part Description
Qty
185-3630
Filter Strap Wrench
3. Remove tube assembly (1) from fuel filter base (2).

4. Disconnect harness assembly (5). Disconnect
hose assemblies (3) and (4).
KENR6052-01
7

2. Use Tooling (A) to remove fuel filters (6).
g01818673
Illustration 8
5. Remove bolt (12) and the washer. Disconnect

harness assemblies (14) and (11) from fuel filter
base (2).
Illustration 9
6. Disconnect hose assembly (9).
3. Remove bolts (8). Disconnect clamps (10).

Relocate the hose assembly.
7. Remove tube assembly (13).

8. Remove bolts (7). Remove fuel filter bases (2).
Remove bolts (8) and the washers. Remove
support assembly (10).
i02630575
Fuel Filter Housing - Remove

(Secondary)
g01852154
4. Disconnect harness assemblies (1), (4), and (5).

Disconnect tube assemblies (3) and (2).
5. Remove bolt (11), the washer, and the spacer.
Relocate the harness assembly.
6. Remove bolts (9). Remove fuel filter base (7).
The weight of fuel filter base (7) is approximately
15 kg (33 lb).
i02634791
SMCS Code: 1262-011
Fuel Filter Housing - Install
S/N: LAJ; LLM1-Up
SMCS Code: 1262-012
Removal Procedure
S/N: SSP; B7B1-Up
Table 2
S/N: EMD; B7C1-Up

Required Tools
S/N: ERM; JTL1-Up
Tool
Part Number
Part Description
Qty
185-3630
Filter Strap Wrench
NOTICE
products.
mandates.
Table 3
Required Tools
Tool
Part Number
Part Description
Qty
185-3630
Filter Strap Wrench
8
KENR6052-01
i02634790
Fuel Filter Housing - Install

SMCS Code: 1262-012
S/N: LAJ; LLM1-Up
Table 4
Required Tools
Illustration 10
g01818673
Tool
Part Number
Part Description
Qty
185-3630
Filter Strap Wrench
1. Position support assembly (10). Install the

washers and bolts (8). Install fuel filter base (2).
Install bolts (7).
2. Install tube assembly (13). Connect hose
assembly (9).
3. Connect harness assemblies (11) and (14) to fuel
filter base (2). Install the washer and bolt (12).
Illustration 12
g01852154
1. Install fuel filter base (7). The weight of fuel filter

base (7) is approximately 15 kg (33 lb). Install
bolts (9).
2. Position the harness assembly and install the
spacer, the washer, and bolt (11).
3. Install tube assemblies (3) and (2). Connect
harness assemblies (5), (4), and (1).
4. Position hose assembly. Connect clamps (10).
Install bolts (8).
5. Use Tooling (A) to install fuel filters (6).
Illustration 11
g01818667
4. Connect harness assembly (5). Connect hose

assemblies (4) and (3).
5. Connect tube assembly (1) to fuel filter base (2).
6. Use Tooling (A) to install fuel filters (6).
7. Turn the fuel supply to the ON position.
KENR6052-01
9
i02944485
Fuel Priming Pump - Remove

and Install
SMCS Code: 1258-010
3. Remove three bolts (2), the mounts, the spacers,

and the washers. Remove bracket assembly (7).
NOTICE
Keep all parts clean from contaminants.
Removal Procedure
NOTICE
Contaminants may cause rapid wear and shortened

component life.

products.
mandates.
NOTICE
component life.
Illustration 14
g01858476
1. Position bracket assembly (7). Install the washers,

the spacers, the mounts, and three bolts (2).
2. Install fuel priming pump (1). Install the nuts, the
washers, and four bolts (6). Connect two harness
assemblies (3). Connect hose assembly (5) to
the IN position. Connect hose assembly (4) to the
OUT position.
Illustration 13
g01858476
2. Disconnect hose assemblies (4) and (5).

Disconnect two harness assemblies (3). Remove
four bolts (6), the washers, and the nuts. Remove
fuel priming pump (1).
10
KENR6052-01
i03482008
Fuel Transfer Pump - Remove

SMCS Code: 1256-011
Removal Procedure
NOTICE
products.
mandates.
NOTICE
Illustration 16
g01820515
3. Remove bolts (8). Remove fuel transfer pump (7).

i03482861
Fuel Transfer Pump - Install

SMCS Code: 1256-012

component life.
Illustration 17
g01820515
1. Install fuel transfer pump (7). Install bolts (8).
Illustration 15
g01820514
2. Disconnect hose assemblies (1), (2), (3), (5), and

(6). Disconnect harness assembly (4).
KENR6052-01
11
NOTICE
products.
mandates.
g01820514
Illustration 18
2. Connect harness assembly (4). Connect hose

assemblies (6), (5), (3), (2), and (1).
Do not open the high pressure fuel system without

allowing the fuel system to purge. After the engine
has shut down, allow the fuel system to purge for
ten minutes. This operating fuel system contains
high pressure. Exposure to high pressure fuel can
result in personal injury.

i03350020
High Pressure Fuel Rails Remove and Install
Note: Use Tooling (A) to cap tube assemblies,

fittings, ports, and any opening in the fuel system in
order to prevent contamination.
SMCS Code: 1274
Removal Procedure
Table 5
Required Tools
Part
Number
Part Description
Qty
339-9354
Fuel LineCap Kit
265-2256
Wipers
Tool
A
Start By:
a. Remove the air inlet manifold. Refer to
Disassembly and Assembly, Air Inlet Manifold Remove and Install.
b. Remove the flow limiters. Refer to Disassembly
and Assembly, Flow Limiters - Remove and
Install.
Illustration 19
g01285837
1. Remove bolt (1) and the clamp from tube

assembly (2).
12
Illustration 20
KENR6052-01
g01822393
Illustration 22
g01285008
Illustration 23
g01822394
Note: Do not remove all the quills in order to maintain

the alignment of the rail.
3. Remove bolts (9). Remove bolts (10) and bolts

(11). Repeat for the opposite side.
Note: Replace with new bolts (9)
4. Remove tube assembly (7). Remove tube
assembly (8) and the O-ring seal.
Illustration 21
g01443406
Note: Cap tube assemblies, fittings, ports, and

any opening in the fuel system in order to prevent
contamination.
2. Disconnect tube assembly (3) and remove the
bolts on tube assembly (2). Remove bolts (5).
Disconnect tube assembly (4). Remove tube
assembly (2) and the O-ring seals. Remove bolts
(6).
Note: If necessary, secondary fuel filter lines may
need to be removed in order to remove tube
assembly (2).
Note: Replace with new bolts (5)
Illustration 24
g01822395
5. Attach a suitable lifting device onto fuel rail (13).

The weight of fuel rail (13) is approximately 60 kg
(131 lb). Remove bolts (12). Remove fuel rail (13).
6. Place the high pressure fuel rail on a clean surface.
Support the rail so the weight is not resting on the
quills. All openings should be capped or plugged
in order to prevent contamination.
7. Repeat Step 5 for the opposite side.
KENR6052-01
13
Table 6
Required Tools
Tool
A
Part
Number
Part Description
Qty
339-9354
Fuel LineCap Kit
265-2256
Wipers
Note: When Tooling (A) is removed be careful to

prevent contamination.
Illustration 25
g01822395
1. Attach a suitable lifting device onto fuel rail (13).

The weight of fuel rail (13) is approximately 60 kg
(131 lb). Install fuel rail (13). Install bolts (12).
g01443632
Illustration 26
2. Tighten bolts (12) in the sequence that is shown

in Illustration 26. Tighten bolts (12) to a torque of
100 20 Nm (74 15 lb ft).
Illustration 28
Illustration 27
g01822394
g01285008
3. Install the new O-ring seals. Lubricate the ends of

tube assembly (8) and the O-ring seals with clean
engine oil. Install new bolts (9) and the washers.
Evenly hand tighten bolts (9) in order to assemble
tube assembly (8) and the O-ring seals. This will
prevent cutting or damage of the O-ring seal.
Install tube assembly (7). Install bolts (10) and
(11) hand tight. Evenly tighten new bolts (9) to a
torque of 20 Nm (15 lb ft).
14
KENR6052-01
Note: Bolts (9) do not rotate more than 90 degrees

at a time.
4. Evenly tighten new bolts (9) to a torque of 40 Nm
(30 lb ft).
Note: Bolts (9) do not rotate more than 45 degrees
at a time.
5. Tighten bolts (10) and (11) to a torque of
40 10 Nm (30 7 lb ft).
6. Install the new O-ring seals into the pump outlet,

the inlet, and the junction block. Lubricate O-ring
seals and the end of tube assemblies (2) and
(4) with clean engine oil. Install new bolts (5)
and washers. Evenly hand tighten new bolts (5)
in order to engage tube assemblies (2) and (4)
with the O-ring seals. This will prevent cutting
or damage of the O-ring seal. Position bolts (6)
and tighten by hand. Evenly hand tighten bolts
(5). Evenly tighten bolts (6) to a torque of 20 Nm
(15 lb ft). Evenly tighten new bolts (5) to a torque
of 20 Nm (15 lb ft). Evenly tighten bolts (6) to a
final torque of 55 10 Nm (41 7 lb ft). Evenly
tighten bolts (5) to a final torque of 40 10 Nm
(30 7 lb ft).
Note: The bolts in tube assembly (2) do not rotate
more than 90 degrees at a time.
7. Evenly tighten the bolts in tube assembly (2) to a
Note: The bolts in tube assembly (2) do not rotate
more than 45 degrees at a time.
Illustration 29
g01443406
Illustration 31
g01285837
8. Install the bracket, the clamp, and bolt (1) onto

tube assembly (2). Use the bracket to adjust the
position of the clamp and bolt (1) for alignment to
tube assembly (2).
9. Repeat this process on the opposite side.
Illustration 30
g01822393
Note: If necessary, secondary fuel filter lines may

need to be installed after tube assembly (2) has been
installed. Do not attempt to push the flanges past
O-ring seals by hand in order to prevent cutting or
damage.
End By:
a. Install the flow limiters. Refer to Disassembly and
Assembly, Flow Limiters - Remove and Install.
b. Install the air inlet manifold. Refer to Disassembly
and Assembly, Air Inlet Manifold - Remove and
Install.
KENR6052-01
15
i03349521
Flow Limiter - Remove and

Install
SMCS Code: 1715-010
Removal Procedure
Table 7
Required Tools
Tool
Part
Number
Part Description
Qty
6V-6195
Interlocking Joint Pliers
Illustration 32
339-9352
Inj. Sys Cap Kit
265-2256
Wipers
1. Remove bolt (3) and the washer. Remove tube

assembly (1). Disconnect harness assembly (2).
g01285474
NOTICE
products.
mandates.
NOTICE
component life.
Illustration 33
g01444306
2. Apply clean engine oil to area (X). Repeat for the

opposite collar. Remove bolts (4) and bolts (6).
Remove tube assembly (5).
Note: Replace with new bolts (4) and (6)

Note: Use Tooling (B) to cap tube assemblies,
fittings, ports, and any opening in the fuel system in
Illustration 34
g01285667
3. Use Tooling (A) to remove flow limiter (7) from the

fuel rail.
16
KENR6052-01
Note: Apply protective caps to flow limiter (7 ) in

order to prevent contamination. Clean Tooling (A)
before using in order to avoid contamination in the
fuel system.
Table 8
Required Tools
Tool
Part
Number
Part Description
Qty
6V-6195
Interlocking Joint Pliers
339-9352
Inj. Sys Cap Kit
265-2256
Wipers
Illustration 36
g01444306
Illustration 37
g01285695
Note: When Tooling (B) is removed be careful to

Illustration 35
g01285667
1. Apply clean engine oil to the sealing face of the

flow limiter and the fuel rail.
Note: Use a clean plastic squirt bottle to apply clean
engine oil. Do not apply clean engine oil by hand.
2. Use Tooling (A) to install flow limiter (7) into the
fuel rail.
3. Apply clean engine oil to area (X). Repeat for

the opposite collar. Apply clean engine oil to the
ends of tube assembly (5). Replace external
O-ring seals on tube assembly (5) and lubricate
the O-ring seals on the tube assembly with clean
engine oil. Install tube assembly (5). Install new
bolts (4) and new bolts (6) hand tight. Evenly
tighten new bolts (4) to a torque of 20 Nm
(15 lb ft). Evenly tighten new bolts (6) to a torque
of 20 Nm (15 lb ft). Evenly tighten new bolts (4) to
a torque of 40 Nm (30 lb ft). Evenly tighten new
bolts (6) to a torque of 40 Nm (30 lb ft).
Note: Clean Tooling (A) before using in order to avoid

contamination in the fuel system.
Illustration 38
g01285474
KENR6052-01
17
4. Connect harness assembly (2). Replace the

O-ring seals on both ends of tube assembly (1).
Install tube assembly (1). Install the washer and
bolt (3).
1. Remove bolts (2). Remove fuel control valve (1).
i02682596
Fuel Control Valve - Remove

and Install
SMCS Code: 1715-010
Removal Procedure
Start By:
g01347728
Illustration 40
a. Remove the fuel pump (high pressure). Refer to

Disassembly and assembly, Fuel Pump (High
Pressure) - Remove and Install.
NOTICE
2. Check O-ring seals (3), (4), and (5) on fuel control

valve (1).
Table 9
Required Tools
Tool
Part Number
Part Description
Qty
5N-5561
Silicone Lubricant

products.
mandates.

Illustration 39
g01347715
Illustration 41
g01347728
1. Lubricate O-ring seals (3), (4), and (5) with Tooling

(A).
18
KENR6052-01
i03591920
Fuel Pump (High Pressure) Remove and Install

SMCS Code: 1288-010
Removal Procedure
Table 10
Required Tools
Tool
Illustration 42
g01347715
A(1)
B
C
(1)
Part Number
Part Description
Qty
138-7575
Link Bracket
6V-3668
12 MM Bolt
5P-8245
Washer
339-9353
High Press. Cap Kit
265-2256
Wipers
246-8191
16 MM Socket
Use one to remove the fuel pump from the EPG engine.
NOTICE
Illustration 43
g01347742
2. Position fuel control valve (1). Install bolts (2).

Tighten bolts (2) in the sequence that is shown
in Illustration 43. Tighten bolts (2) to a torque of
6 Nm (53 lb in). Tighten bolts (2) in the sequence
that is shown in Illustration 43. Tighten bolts (2) to
a torque of 12 Nm (106 lb in).
End By:
a. Install the fuel pump (high pressure). Refer to
Disassembly and assembly, Fuel Pump (High
Pressure) - Remove and Install.

products.
mandates.
NOTICE
component life.

fittings, ports, and any openings on the fuel system
in order to prevent contamination.
KENR6052-01
Illustration 44
19
g01824814
1. Remove hose assemblies (1), (2), and (6).

Remove bolt (4) and hose assembly (7). Remove
clamp assembly (8) and remove hose assembly
(3). Disconnect harness assembly (5).
g01825193
Illustration 46
Note: When the fuel lines are removed, use clean

engine oil to lubricate the outside diameter of tube
assembly (20) in area (X). Use Tooling (C) in order
to remove bolts (16) and (19). If the procedure is not
followed, contamination and fuel leaks may occur.
3. Remove bolt (18), the washer, and the nut.
Remove clamp assembly (17). Remove bolts (16)
and (19). Remove tube assembly (20) and the
O-ring seals.
4. Use Tooling (A) and attach a suitable lifting device
onto fuel pump (15). The weight of fuel pump (15)
is approximately 102 kg (225 lb). Remove bolts
(21). Lower fuel pump (15) to the ground.
Illustration 45
g01824815
2. Remove bolts (10) and the washers. Disconnect

harness assembly (13) from the fuel pump.
Remove tube assembly (9). Remove hose
assembly (14). Remove bolt (12) and the washer.
Remove plate assembly (11).
Note: The lifting device should not come into contact

with the fuel shutoff valve. This will result in damage
to the component.
Table 11
Required Tools
Tool
A(1)
Part Description
Qty
138-7575
Link Bracket
6V-3668
12 MM Bolt
5P-8245
Washer
339-9353
High Press Cap Kit
265-2256
Wipers
246-8191
16 MM Socket
1P-0808
Multipurpose Grease
(1)
Part Number
Use one to remove the fuel pump from the EPG engine.
20
KENR6052-01

g01824815
Illustration 48
4. Position plate assembly (11) and install the washer

and bolt (12). Install hose assembly (14). Install
tube assembly (9). Connect harness assemblies
(13) and install the washers and bolts (10).
Illustration 47
g01825193

onto fuel pump (15). The weight of fuel pump (15)
is approximately 102 kg (225 lb). Raise fuel pump
(15) into position on the engine. Install bolts (21).
2. Lubricate the O-ring seals with clean engine
oil. Lubricate the ends of tube assembly (20)
with Tooling (D). Install the O-ring seals on tube
assembly (20). Install tube assembly (20). Install
bolts (19) hand tight. Install bolts (16) hand tight.
Position clamp assembly (17). Install bolt (18), the
washer, and the nut. Use Tooling (C) and evenly
tighten bolts (19) to a torque of 20 Nm (15 lb ft).
Use Tooling (C) and evenly tighten bolts (16) to a
Note: Do not rotate bolts (19) and (16) more than 90
degrees at a time.
Illustration 49
3. Evenly tighten bolts (19) to a torque of 40 Nm

(30 lb ft). Evenly tighten bolts (16) to a torque of
40 Nm (30 lb ft). Tighten bolt (18).
5. Connect harness assembly (5). Install hose

assembly (3) and clamp assembly (8). Install hose
assembly (7) and bolt (4). Install hose assemblies
(6), (2), and (1).
g01824814

degrees at a time.
i03634303
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
Table 12
Required Tools
Tool
Part Number
138-7573
Part Description
Link Bracket
Qty
1
KENR6052-01
21
Start By:
a. Remove the air cleaners. Refer to Disassembly
and Assembly, Air Cleaner - Remove and Install.
NOTICE
component life.
NOTICE
products.
Illustration 51
g01826997
5. Attach Tooling (A) and a suitable lifting device onto

turbocharger (7). The weight of turbocharger (7)
is approximately 85 kg (187 lb).
6. Loosen clamp (10).
7. Remove bolts (9) and the washers. Remove
turbocharger (7).

mandates.
Illustration 52
Illustration 50
g01826715
1. Remove hose assemblies (1), (2), and (3).

3. Disconnect sensor (5) from turbocharger (7).
4. Loosen clamps (6) and remove the bellows .
g01949854
8. Remove screen assembly (8) from turbocharger

support (10) and inspect. Remove O-ring seal (9).
9. Repeat Steps 1 through 7 for the remaining
turbochargers.
22
KENR6052-01
i03634304
Turbocharger - Install
SMCS Code: 1052-012
Table 13
Required Tools
Tool
Part Number
138-7573
Part Description
Link Bracket
Qty
1
Illustration 54
NOTICE
component life.
NOTICE
g01826997
2. Attach Tooling (A) and a suitable lifting device

onto turbocharger (7). The weight of turbocharger
(7) is approximately 85 kg (187 lb). Position
turbocharger (7). Install the washers and bolts (9).
3. Tighten clamp assemblies (10) to a torque of
12 2 Nm (106 18 lb in).

products.
mandates.
Illustration 55
g01826715
4. Position the bellows and install clamps (6).

Tighten clamps (6) to a torque of 12 2 Nm
(106 18 lb in). Tap clamps (6) all around
and tighten again to a torque of 12 2 Nm
(106 18 lb in).
5. Connect hose assemblies (8) and (4).
6. Install hose assemblies (3), (2), and (1).
7. Connect sensor (5) to turbocharger (7).
Illustration 53
g01949854
1. Install clean screen assembly (8) into turbocharger

support (10). Install new O-ring seal (9).
End By:
a. Install the air cleaners. Refer to Disassembly and
Assembly, Air Cleaner - Remove and Install.
KENR6052-01
23
i02635840
Air Inlet Manifold - Remove

and Install
2. Install top bolts (1) and tighten top and bottom

bolts. Tighten bolts (1) to a torque of 55 10 Nm
(41 7 lb ft).
SMCS Code: 1058-010
3. If necessary, remove the air inlet manifold in

sections. Tighten the clamp assemblies to a
torque of 7.5 1 Nm (66 9 lb in).
Removal Procedure
4. Connect the harness assembly.

i02636137
Exhaust Elbow - Remove and

Install
SMCS Code: 1060-010
Removal Procedure
Table 14
Required Tools
Illustration 56
g01321426
1. Disconnect the harness assembly.
Tool
Part Number
138-7573
Part Description
Link Bracket
Qty
2
2. Attach a suitable lifting device onto air inlet

manifold (2). The weight of air inlet manifold (2) is
approximately 69 kg (150 lb). Remove top bolts
(1) and loosen bottom bolts.
Note: The air inlet manifold can be removed in
sections, if necessary.
3. Remove air inlet manifold (2).
Illustration 58
g01704859
1. Remove bolts (3) and the washers. Remove bolts

(2), the washers, and the nuts from platform
assembly (1).
Illustration 57
g01321426
1. Attach a suitable lifting device onto air inlet

manifold (2). The weight of air inlet manifold (2)
is approximately 69 kg (150 lb). Position air inlet
manifold (2).

onto platform assembly (1). The weight of platform
assembly (1) is approximately 28 kg (63 lb).
Remove platform assembly (1).
exhaust elbow (5). The weight of exhaust elbow
(5) is approximately 95 kg (209 lb). Loosen clamps
(6). Remove bolts (4). Remove exhaust elbow (5).
24
KENR6052-01
i02636539
Exhaust Manifold - Remove

and Install
Table 15
Required Tools
Tool
Part Number
138-7573
Part Description
Link Bracket
Qty
SMCS Code: 1059-010
Removal Procedure
Illustration 60
g01851633
1. Remove clamps (1). Remove exhaust bellow (3).

Remove clamps (2). Remove exhaust bellow (4).
Illustration 59
g01704859

onto exhaust elbow (5). The weight of exhaust
elbow (5) is approximately 95 kg (209 lb). Position
exhaust elbow (5). Install bolts (4).
2. Tighten clamp assemblies (6) to a torque of
12 2 Nm (106 18 lb in). Tap the clamp
assemblies all around. Repeat tightening clamp
assemblies (6) to a torque of 12 2 Nm
(106 18 lb in).
onto platform assembly (1). The weight of platform
assembly (1) is approximately 28 kg (63 lb).
Position platform assembly (1).
4. Install the washers, bolts (3), and the nuts. Install
the washers and bolts (2) in platform assembly (1).
Illustration 61
g01321966
2. Attach a suitable lifting device onto exhaust

manifolds (5). The weight of exhaust manifolds (5)
is approximately 82 kg (180 lb). Loosen clamp (6).
3. Remove bolts (7) from exhaust manifolds (5).
Loosen bolts (8). Remove exhaust manifolds (5).
KENR6052-01
25
g01851634
Illustration 62
4. Remove exhaust manifold (9).

5. Repeat Steps 1 through 4 for the opposite side.
Illustration 64
Table 16
Required Tools
Tool
Part Number
Part Description
Qty
4C-5597
Anti-seize Compound
g01321966
2. Attach a suitable lifting device onto exhaust

manifolds (5). The weight of exhaust manifolds (5)
is approximately 82 kg (180 lb). Position exhaust
manifolds (5). Tighten clamp assemblies (6) to a
torque of 12 2 Nm (106 18 lb in).
3. Apply Tooling (A) to bolts (7). Install bolts (7) in
exhaust manifolds (5). Tighten bolts (7) and (8) to
a torque of 65 5 Nm (48 4 lb ft).
Illustration 63
g01851634
1. Position exhaust manifold (9).

Illustration 65
g01851633
4. Install exhaust bellow (4). Install clamp assemblies

(2). Install exhaust bellow (3). Install clamp
assemblies (1). Tighten clamp assemblies (1) and
(2) to a torque of 12 2 Nm (106 18 lb in).
26
KENR6052-01
i02636698
Water Pump - Remove
3. Remove bolts (6). Disconnect elbow (7). Remove

the O-ring seal.
onto water pump (1). The weight of water pump
(1) is approximately 44 kg (97 lb). Disconnect
hose assembly (2). Remove bolts (5) and remove
water pump (1).
SMCS Code: 1361-011
Removal Procedure
Table 17
Required Tools
i02088955
Tool
Part Number
Part Description
Qty
138-7573
Link Bracket
NOTICE
products.
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.
Water Pump - Disassemble

SMCS Code: 1361-015
Disassembly Procedure
Table 18
Required Tools
Tool
Part
Number
1P-0510
Part Description
Qty
Driver Gp
1 inch by 4 inch steel plate
248-3311
Holding Fixture
248-3310
Locknut Wrench
8H-0663
Bearing Puller Gp
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
NOTICE
component life.
Illustration 66
g01323569
2. Remove bolts (3). Remove elbow (4). Remove the

O-ring seal from elbow (4).
KENR6052-01
Illustration 67
27
g01036014
Illustration 69
g01035285
1. Remove plug (1) and plug (2) from bearing

housing (3). Remove plug (6) from housing (5).
Remove the O-ring seals from the plugs.
4. Install Tooling (B) under impeller (9). Use a

suitable press and Tooling (A) to remove the
impeller.
2. Remove water pump filter (4) from bearing

housing (3).
Note: Do not allow bearing housing (3) to fall to the

floor when the impeller is removed from the pump
shaft.
Illustration 68
g01035264
Illustration 70
3. Remove bolts (7) and washers. Remove bearing

housing (3) from housing (5). Remove O-ring seal
(8) from bearing housing (3).
g01035309
5. Remove socket head bolts (10). Remove retainer

(11) and pump shaft (12) from bearing housing (3).
Note: Spring (14) and ceramic seal (13) will be
removed from the shaft assembly when the pump
shaft is removed from the bearing housing.
28
KENR6052-01
g01035437
Illustration 73
8. Remove ceramic seal (18) and lip seal (19) from

bearing housing (3).
Illustration 71
g01035407
i02088665
Water Pump - Assemble
6. Install pump shaft (12) in Tooling (C). Loosen set

screws (15). Use Tooling (D) to remove bearing
locknut (16) from the pump shaft.
SMCS Code: 1361-016
Note: The splined end of the pump shaft is marked

in order to indicate either RH threads or LH threads
on the pump shaft.
Table 19
Assembly Procedure
Required Tools
Tool
Part
Number
1P-0510
Driver Gp
248-3311
Holding Fixture
248-3310
Locknut Wrench
8H-0663
Bearing Puller Gp
1U-6396
O-Ring Assembly
Compound
7N-8268
Installation Tool
8H-8581
Feeler Gauge
G
H
Part Description
Qty
NOTICE
Illustration 72
g01035429
7. Use Tooling (E) to remove bearing assembly (17)

from pump shaft (12).

component life.
KENR6052-01
29
Note: The torque wrench must be 90 degrees to

Tooling (D).
6. Install set screws (15) and tighten to a torque of
4 1 Nm (35 9 lb in).
Illustration 76
Illustration 74
g01035690
g01040290
1. Use Tooling (E) and a suitable press to install

bearing assembly (17) on pump shaft (12).
2. Install bearing cone (23) on the pump shaft.
3. Install spacer (22) and bearing cups (21) on the
pump shaft.
Note: Do not damage the wear surfaces of the

carbon ring or the ceramic ring. Do not touch the
wear surfaces of the carbon ring or the ceramic ring.
Install the ceramic ring with the smoothest face of the
ring toward the carbon seal.
7. Apply Tooling (F) to the outside diameter of
ceramic seal (18). Use Tooling (G) and hand
pressure to install ceramic seal (18) in bearing
housing (3).
Illustration 77
g01035699
8. Use Tooling (A) and a suitable press to install lip

seal (19) in bearing housing (3). Ensure that the
lip is toward the outside.
Illustration 75
g01035607
5. The splined end of the pump shaft is marked in

order to indicate either RH threads or LH threads
on the pump shaft. Install bearing locknut (16).
Use Tooling (D) on the bearing locknut. Tighten
the bearing locknut to a torque of 300 30 Nm
(221 22 lb ft).
Note: Install the lip seal dry. Install the lip seal within
two minutes of removal from the shipping sleeve.
30
KENR6052-01
11. Apply Tooling (F) to the inside diameter of ceramic

seal (13). Use hand pressure and the tool that is
supplied with the water pump seal group to install
the ceramic seal. The face of ceramic seal (13)
should make light contact with ceramic seal (18).
12. Install spring (14).
13. Lubricate pump shaft (12) on bearing housing (3)
with clean engine oil. Position impeller (9) on the
pump shaft.
Illustration 78
g01035809
9. Lubricate pump shaft (12) with clean engine oil.

Install the pump shaft in bearing housing (3).
Install retainer (11). Install socket head bolts (10)
and tighten to a torque of 12 3 Nm (9 2 lb ft).
Illustration 80
g01035846
14. Place bearing housing (3) on impeller (9). Use

a suitable press and press pump shaft (12) into
the impeller. Install the impeller so the dimension
between the impeller and the pump shaft is
0.000 0.076 mm (0.0000 0.0030 inch).
Illustration 79
g01035829

10. Remove spring (14) from ceramic seal (13).
Illustration 81
g01035264
KENR6052-01
31
15. Install O-ring seal (8) on bearing housing (3).

Lubricate the O-ring seal with clean engine oil.
16. Position bearing housing (3) in housing (5). Install
washers and bolts (7) finger tight.
22. Install water pump filter (4) in bearing housing (3).

End By:
a. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install.
i02636819
Water Pump - Install

SMCS Code: 1361-012
Table 20
Required Tools
Illustration 82
g01036084
Tool
Part Number
Part Description
Qty
138-7573
Link Bracket
17. Tighten the bolts in a numerical sequence to a

torque of 50 9 Nm (35 7 lb ft).
18. Use Tooling (H) and measure the gap between
the impeller and the pump housing. The minimum
gap between the impeller and the pump housing
is 0.20 mm (0.008 inch).
Illustration 84
g01323569

onto water pump (1). The weight of water pump
(1) is approximately 44 kg (97 lb). Position water
pump (1) onto the engine and install bolts (5).
Connect hose assembly (2).
Illustration 83
g01036014
19. Install the O-ring seal on plug (6). Install the plug
in housing (5). Tighten the plug to a torque of
177 7 Nm (131 6 lb ft).
in bearing housing (3). Tighten the plug to a torque
of 8 1 Nm (6 1 lb ft).
of 17 1 Nm (12 1 lb ft).
2. Position the O-ring seal and elbow (7). Install bolts

(6).
3. Position the O-ring seal onto elbow (4). Install
elbow (4). Install bolts (3).
4. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, Cooling
System Coolant - Change.
32
KENR6052-01
i03490381
Fuel and Auxiliary Water Pump

Drive - Remove and Install
SMCS Code: 1288-010; 1371-010-DRV
Removal Procedure
Table 21
Required Tools
Tool
Part Number
Part Description
Qty
138-7575
Link Bracket
1P-0520
Driver Gp
Illustration 86
g01213648
2. Remove O-ring seals (3) from housing (1).

Start By:
a. Remove the fuel pump. Refer to Disassembly and
Assembly, Fuel Pump (Manifold) - Remove and
Install.
b. Remove the auxiliary water pump. Refer to
Disassembly and Assembly, Auxiliary Water
Pump - Remove.
Illustration 87
g01213659
3. Use Tooling (B) and a suitable press in order to

remove bearing (4) from housing (1).
Illustration 85
g01827734

onto housing (1). The weight of housing (1) is
approximately 23 kg (50 lb). Remove bolts (2).
Remove housing (1).
Illustration 88
g01827737
4. Remove the fuel and auxiliary water pump drive

gear (5).
KENR6052-01
33
Table 22
Required Tools
Illustration 89
Tool
Part Number
Part Description
Qty
138-7575
Link Bracket
1P-0520
Driver Gp
g01215057
5. Remove bolts (6). Remove adapter (7).
Illustration 92
g01215071

install bearing (10) into adapter (7).
Illustration 90
g01215060
6. Remove O-ring seals (8) and (9).
Illustration 93
g01215060
Note: Check the O-ring seals for wear or for damage.

If necessary, replace the O-ring seals.
2. Install O-ring seals (8) and (9).
Illustration 91
g01215061

remove bearing (10) from adapter (7).
34
Illustration 94
KENR6052-01
g01215057
3. Install adapter (7). Install bolts (6).
Illustration 97
g01213648

6. Install O-ring seals (3) into housing (1).
Illustration 95
g01827737
4. Install the fuel and auxiliary water pump drive gear

(5).
Illustration 98
g01827734

onto housing (1). The weight of housing (1) is
approximately 23 kg (50 lb). Position housing (1).
Install bolts (2).
End By:
a. Install the auxiliary water pump. Refer to
Pump - Install.
Illustration 96
g01213693

install bearing (4) into housing (1).
b. Install the fuel pump. Refer to Disassembly and

Assembly, Fuel Pump (Manifold) - Remove and
Install.
KENR6052-01
35
i02637878
Auxiliary Water Pump Remove
2. Disconnect tube assembly (1). Remove bolts (3).

Remove elbow (4). Remove bolts (6). Remove
elbow (7).
onto auxiliary water pump (2). The weight of
auxiliary water pump (2) is approximately 31 kg
(69 lb). Remove nuts (5). Remove auxiliary water
pump (2).
SMCS Code: 1371-011
Removal Procedure
Table 23
i02638305
Required Tools
Tool
Part Number
Part Description
Qty
138-7573
Link Bracket
NOTICE
products.
mandates.
1. Drain the coolant from the auxiliary cooling system
into a suitable container for storage or for disposal.
Illustration 99
Auxiliary Water Pump Disassemble

SMCS Code: 1371-015
Table 24
Required Tools
Tool
Part Number
1P-0510
Part Description
Qty
Driver Gp
1 inch by 4 inch
steel plate
248-3311
Holding Fixture
248-3310
Spanner Wrench
8H-0663
Bearing Puller Gp
Start By:
a. Remove the auxiliary water pump. Refer to
Pump - Remove.
g01323519
Illustration 100
g01036014
36
KENR6052-01
1. Remove plugs (1) and (2) from bearing housing

(3). Remove plug (6) from housing (5). Remove
the O-ring seals from the plugs.
2. Remove water pump filter (4) from bearing
housing (3).
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
4. Install Tooling (B) under impeller (9). Use a
suitable press and Tooling (A) to remove impeller
(9).
Note: Do not allow bearing housing (3 ) to fall to the
floor when the impeller is removed from the pump
shaft.
Illustration 101
g01035264

bearing housing (3) from housing (5). Remove
O-ring seal (8) from bearing housing (3).
Illustration 103
g01035309
5. Remove socket head bolts (10). Remove retainer

(11) and pump shaft (12) from bearing housing (3).
Note: Spring (14) and ceramic seal (13) will be
removed from the shaft assembly when the pump
shaft is removed from the bearing housing.
Illustration 102
g01035285
KENR6052-01
37
g01035437
Illustration 106
8. Remove ceramic seal (18) and lip seal (19) from

bearing housing (3).
Illustration 104
g01035407
6. Install pump shaft (12) in Tooling (C). Loosen set

screws (15). Use Tooling (D) to remove bearing
locknut (16) from the pump shaft.
Note: The splined end of the pump shaft is marked
in order to indicate either RH threads or LH threads
on the pump shaft.
i02638976
Auxiliary Water Pump Assemble

SMCS Code: 1371-016
Assembly Procedure
Table 25
Required Tools
Tool
Part Number
Part Description
Qty
1P-0510
Driver Gp
248-3311
Holding Fixture
248-3310
Spanner Wrench
8H-0663
Bearing Puller Gp
1U-6396
O-Ring Assembly
Compound
7N-8268
Installation Tool
8H-8581
Feeler Gauge
NOTICE
Illustration 105
g01035429
7. Use Tooling (E) to remove bearing assembly (17)

from pump shaft (12).

component life.
38
KENR6052-01
Note: The torque wrench must be 90 degrees to

Tooling (D).
6. Install set screws (15) and tighten to a torque of
4 1 Nm (35 9 lb in).
Illustration 109
Illustration 107
g01035690
g01040290
1. Use Tooling (E) and a suitable press to install

assembly (17) on pump shaft (12).
3. Install spacer (22) and bearing cups (21) on the
pump shaft.

7. Apply Tooling (F) to the outside diameter of
ceramic seal (18). Use Tooling (G) and hand
pressure to install ceramic seal (18) into bearing
housing (3).
Illustration 110
g01035699
8. Use Tooling (A) and a suitable press to install lip

seal (19) into bearing housing (3). Ensure that the
lip is toward the outside.
Illustration 108
g01035607
5. The splined end of the pump shaft is marked in

order to indicate either RH threads or LH threads
on the pump shaft. Install bearing locknut (16).
Use Tooling (D) on the bearing locknut and tighten
the bearing locknut to a torque of 300 30 Nm
(221 22 lb ft).
Note: Install the lip seal dry. Install the lip seal within
two minutes of removal from the shipping sleeve.
KENR6052-01
39

10. Remove spring (14) from ceramic seal (13).
11. Apply Tooling (F) to the inside diameter of ceramic
seal (13). Use hand pressure and the tool that is
supplied with the water pump seal group to install
the ceramic seal. The face of ceramic seal (13)
should make light contact with ceramic seal (18).
12. Install spring (14).
13. Lubricate pump shaft (12) on bearing housing (3)
with clean engine oil. Position impeller (9) on the
pump shaft.
Illustration 111
g01035809
9. Lubricate pump shaft (12) with clean engine oil.

Install the pump shaft in bearing housing (3). Install
retainer (11). Install socket head bolts (10) and
tighten to a torque of 12 3 Nm (106 27 lb in).
Illustration 113
g01035846
14. Place bearing housing (3) on impeller (9). Use

a suitable press and press pump shaft (12) into
the impeller. Install the impeller so the dimension
between the impeller and the pump shaft is
0.000 .076 mm (0.0000 0.0030 inch).
Illustration 112
g01035829
Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.
40
Illustration 114
KENR6052-01
g01035264
15. Install O-ring seal (8) on bearing housing (3).

Lubricate the O-ring seal with clean engine oil.
16. Position bearing housing (3) in housing (5). Install
washers and bolts (7) finger tight.
g01036014
Illustration 116
in housing (5). Tighten the plug to a torque of
177 7 Nm (131 6 lb ft).
of 8 1 Nm (71 9 lb in).
of 17 1 Nm (12 1 lb ft).
22. Install water pump filter (4) in bearing housing (3).
End By:
a. Install the auxiliary water pump. Refer to
Pump - Install.
Illustration 115
g01036084
i02639341
17. Tighten the bolts in a numerical sequence to a

18. Use Tooling (H) and measure the gap between
the impeller and the pump housing. The minimum
gap between the impeller and the pump housing
is 0.20 mm (0.008 inch).
Auxiliary Water Pump - Install

SMCS Code: 1371-012
Table 26
Required Tools
Tool
Part Number
Part Description
Qty
138-7573
Link Bracket
KENR6052-01
41
1. Drain the coolant from the engine into a suitable

container for storage or for disposal. Refer to
Illustration 118
Illustration 117
g01323519

onto auxiliary water pump (2). The weight of
auxiliary water pump (2) is approximately 31 kg
(69 lb). Position auxiliary water pump (2). Install
nuts (5).
g01828273
2. Attach a suitable lifting device onto engine oil

cooler (1). The weight of engine oil cooler (1) is
2. Install hose assembly (1). Position elbow (7).

Install bolts (6). Position elbow (4). Install bolts (3).
3. Fill the auxiliary cooling system with coolant. Refer
to Operation and Maintenance Manual, Cooling
i02640109
Engine Oil Cooler - Remove

SMCS Code: 1378-011
Removal Procedure
Illustration 119
g01828274
3. Remove bolts (4). Remove elbow (3). Disconnect

hose assembly (2). Remove bolts (6). Disconnect
tube assembly (5).
NOTICE
products.
mandates.
Illustration 120
g01707194
4. Remove hose assembly (7). Remove three clamp

assemblies (9). Remove tube assembly (8).
42
KENR6052-01
7. Lower engine oil cooler (1) to the ground.

i02640714
Engine Oil Cooler Disassemble

SMCS Code: 1378-015
Start By:
Illustration 121
g01828793

Remove bolts (12). Disconnect tube assembly
(13).
Illustration 122
a. Remove the engine oil cooler. Refer to

Disassembly and Assembly, Engine Oil Cooler
- Remove.
g01829254
6. Lower engine oil cooler (1) and engine oil lines

group (15). Remove bolts (14) and engine oil lines
group (15).
Illustration 124
g01324702
1. Remove bolts (3). Remove elbow (4) and the

O-ring seals. Repeat for the opposite side.
Illustration 125
Illustration 123
g01403583
g01200526
2. Remove bolts (5). Remove bonnet (6) and the

gaskets. Repeat for the opposite side.
KENR6052-01
43
i02640746
i02640792
Engine Oil Cooler - Assemble
Engine Oil Cooler - Install
SMCS Code: 1378-016
SMCS Code: 1378-012
Assembly Procedure
NOTICE
products.
Illustration 126
g01200526

mandates.
1. Position the gaskets and bonnet (6). Install bolts

(5).
Illustration 128
Illustration 127
g01324702
2. Position the O-ring seals and elbow (4). Install

bolts (3).
End By:
a. Install the engine oil cooler. Refer to Disassembly
and Assembly, Engine Oil Cooler - Install.
g01403583
1. Attach a suitable lifting device onto engine oil

cooler (1). The weight of engine oil cooler (1) is
44
Illustration 129
KENR6052-01
g01829254
2. Position engine oil lines group (15) on engine oil

cooler (1) and install bolts (14). Position engine oil
cooler (1) on the side of the engine cylinder block.
g01828274
Illustration 132
5. Connect tube assembly (5). Install bolts (6).

Connect hose assembly (2). Position elbow (3).
Install bolts (4).
Operation and maintenance Manual, Cooling
i02640983
Engine Oil Pump - Remove

SMCS Code: 1304-011
Removal Procedure
Table 27
Illustration 130
g01828793
3. Connect hose assemblies (10) and (11). Connect

tube assembly (13). Install bolts (12).
Required Tools
Tool
Part Number
138-7575
Part Description
Link Bracket
Qty
2
NOTICE
products.
Illustration 131
g01707194
4. Position tube assembly (8) and install three clamp

assemblies (9). Leave middle clamp assembly (9)
loose until clamp assemblies (9) at each end are
tightened. Adjust middle clamp assembly (9) and
tighten. Install hose assembly (7).

mandates.
KENR6052-01
Illustration 133
45
g01829554
1. Remove bolts (2). Loosen clamps (3). Remove the

end section of air inlet manifold (1) and gaskets
(4).
2. Disconnect hose assemblies (5) and (7). Remove
bolts (6) and tube assembly (8).
Illustration 135
g01830494
5. Attach a suitable lifting device onto regulator

assembly (17). The weight of regulator assembly
(17) is approximately 51 kg (113 lb). Disconnect
harness assembly (16). Remove bolts (20).
Remove regulator assembly (17).
6. Remove bolt (19) and the bracket bolts. Remove
mounting group (18) for the alternator.
7. Remove the nuts, the washers, and plate (24).
Remove elbow (23). Remove the bolts and
adapter (22) with the O-ring seals from engine oil
pump (21).
Illustration 134
g01830493
3. Remove bolts (9) and (11). Remove tube

assembly (10) and flanges (12).
4. Remove bolts (14). Remove elbow (13) and
bonnet (15).
Illustration 136
g01830495

onto engine oil pump (21). The weight of engine
oil pump (21) is approximately 67 kg (148 lb).
Remove bolts (25). Lower engine oil pump (21)
from the engine.
46
Illustration 137
KENR6052-01
g01830496
Personal injury can result from parts and/or covers under spring pressure.
Illustration 139
g01405649
11. Remove spring (31), retainer (30), shims (29), and

stem (28) for the maximum pressure relief valve
from regulator assembly (17). Remove spring
(35), retainer (34), shims (33), and stem (32) for
the regulator valve from regulator assembly (17).
Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the
bolts are loosened.
9. Remove the bolts and cover (26) from regulator
assembly (17).
Illustration 138
Illustration 140
g01405650
Illustration 141
g01405651
g01595844
10. Remove O-ring seals (27).
12. Remove bolts (36). Remove housing (37).

Remove bolts (38). Remove tube (39). Remove
O-ring seal (40). Remove O-ring seals (41).
KENR6052-01
47
i02402563
Engine Oil Pump - Disassemble

SMCS Code: 1304-015
Start By:
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump
- Remove.
Illustration 144
g01199947
3. Remove bushings (4) from cover (2).
Illustration 142
g01199893
1. Remove bolts (1) and the washers. Remove cover

(2).
Illustration 145
g01199949
4. Remove gears (5) and shafts (6) from oil pump

housing (7).
Illustration 143
g01199895
2. Remove O-ring seal (3) from cover (2).

Illustration 146
g01199952
5. Remove bushings (8) from oil pump housing (7).
48
KENR6052-01
g01199954
Illustration 147
6. Remove O-ring seals (9) and (10).
Illustration 149
g01199954

i02402769
Engine Oil Pump - Assemble

SMCS Code: 1304-016
Assembly Procedure
Table 28
Required Tools
Tool
Part Number
Part Description
Qty
1P-0510
Driver Gp
1
Illustration 150
g01199949
3. Install shafts (6) and gears (5) into oil pump

housing (7).
Illustration 148
g01200020
1. Use Tooling (A) and a suitable press in order to

install bushings (8) into oil pump housing (7).
Illustration 151
g01200032

install bushings (4) into cover (2).
KENR6052-01
49
g01199895
Illustration 152
Illustration 154
g01405651
Illustration 155
g01405650
5. Install O-ring seal (3) into cover (2).
g01199893
Illustration 153
6. Position cover (2). Install the washers and bolts

(1).
1. Install O-ring seals (41). Install O-ring seal (40).

Install tube (39). Install bolts (38). Install housing
(37). Install bolts (36).
End By:
a. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install.
i02641093
Engine Oil Pump - Install

SMCS Code: 1304-012
Illustration 156
g01405649
Table 29
Required Tools
Tool
Part Number
138-7575
Part Description
Link Bracket
Qty
2
2. Install stem (32), shims (33), retainer (34), and

spring (35) for the regulator valve into regulator
assembly (17). Install stem (28), shims (29),
retainer (30), and spring (31) for the maximum
pressure relief valve into regulator assembly (17).
50
KENR6052-01

onto engine oil pump (21). The weight of engine
oil pump (21) is approximately 67 kg (148 lb).
Position engine oil pump (21) onto the engine.
Install bolts (25).
Illustration 157
g01595844
3. Install O-ring seals (27).
Illustration 160
Illustration 158
g01830496
g01830494
6. Install the O-ring seals on engine oil pump (21).

Install adapter (22) and the bolts onto engine oil
pump (21). Install the O-ring seals and elbow (23)
. Position plate (24) and install the washers and
the nuts.
7. Position mounting group (18) for the alternator.
Install the bracket bolts. Install bolt (19).

8. Attach a suitable lifting device onto regulator

assembly (17). The weight of regulator assembly
regulator assembly (17) on the engine oil pump
(21). Install the nut and bolts (20). Connect
harness assembly (16).
4. Install cover (26) and the bolts onto regulator

assembly (17).
Illustration 161
Illustration 159
g01830495
g01830493
9. Position bonnet (15) and elbow (13). Install bolts

(14).
KENR6052-01
51
10. Position flanges (12) and tube assembly (10).

Install bolts (9) and (11).
Illustration 162
g01829554
11. Position tube assembly (8) and install bolts (6).

Connect hose assemblies (7) and (5).
12. Install gaskets (4) and the end section of air inlet
manifold (1). Connect clamps (3). Install bolts (2).
i02641484
Engine Oil Filter Housing Remove

SMCS Code: 1306-011
Removal Procedure
NOTICE
products.
mandates.
1. Drain the oil from the engine oil filter housing into
Illustration 163
g01832337
2. Attach a suitable lifting device onto engine oil filter

housing (1). The weight of engine oil filter housing
(1) is approximately 83 kg (183 lb). Remove bolts
(3). Disconnect tube assembly (5). Remove bolts
(4). Disconnect tube assembly (6). Disconnect
3. Remove clamps (8). Remove bolts (7) and lower
engine oil filter housing (1).
52
KENR6052-01
i02641614
Engine Oil Filter Housing Install
Start By:
a. Remove the engine oil pump. Refer to
- Remove.
SMCS Code: 1306-012
Illustration 165
g01200542
1. Remove bolts (1). Remove cover (2).
g01832337
Illustration 164
1. Attach a suitable lifting device onto engine oil filter

housing (1). The weight of engine oil filter housing
engine oil filter housing (1) and bracket assembly
onto the engine. Install bolts (7). Install clamps (8).
2. Connect harness assembly (2). Position tube
assembly (6) and install bolts (4). Position tube
assembly (5) and install bolts (3).
Illustration 166
g01200648
2. Remove O-ring seals (3 ) and (4).
3. Check the engine oil level. Refer to Operation and

Maintenance Manual, Engine Oil Level - Check.
i02403974
Engine Oil and Water Pump

Drive - Remove
SMCS Code: 1313-011
Removal Procedure
Table 30
Illustration 167
g01200650
Required Tools
Tool
Part Number
Part Description
Qty
1P-0520
Driver Gp

remove bearing (5) from cover (2).
KENR6052-01
Illustration 168
53
g01200652
4. Remove engine oil and water pump drive (6).
Illustration 170
g01200684
2. Remove spacer (2), gear (3), and pump drive

shaft (4).
i02404076

Drive - Disassemble
SMCS Code: 1313-015
i02404086

Drive - Assemble
SMCS Code: 1313-016
Assembly Procedure
Start By:
a. Remove the engine oil and water pump drive.
Refer to Disassembly and Assembly, Engine Oil
and Water Pump Drive - Remove.
Illustration 171
g01200684
1. Position pump drive shaft (4), gear (3), and spacer

(2).
Illustration 169
1. Remove bolts (1).
g01200678
54
Illustration 172
KENR6052-01
g01200678
Illustration 174
g01200650

install bearing (5) into cover (2).
2. Install bolts (1).

End By:
a. Install the engine oil and water pump drive. Refer
to Disassembly and Assembly, Engine Oil and
Water Pump Drive - Install.
i02404092

Drive - Install
SMCS Code: 1313-012
Illustration 175
g01200648

Illustration 173
g01200652
1. Install engine oil and water pump drive (6).
Illustration 176
g01200542
4. Position cover (2). Install bolts (1).

End By:
a. Install the engine oil pump. Refer to Disassembly
KENR6052-01
55
i02642013
Engine Oil Screen - Remove

and Install
SMCS Code: 1308-010-Z3
Removal Procedure
Table 31
Required Tools
Tool
Part Number
Part Description
Qty
185-3630
Filter Strap Wrench
NOTICE
products.
Illustration 178
g01711679
3. Remove Clamps (2). Use Tooling (A) to remove

oil filters (1).
4. Remove bolts (3), the washers and the spacers.
Remove bracket (4).
5. Remove two nuts (7) and the washers. Remove
bracket (6) and relocate harness assembly (5).
6. Use Tooling (A) to remove fuel filters (8). Relocate
hose assembly (9).

mandates.
1. Drain the engine oil into a suitable container for
storage or for disposal. Refer to Operation and
Maintenance Manual, Engine Oil and Filter Change.
Illustration 179
g01711680
7. Remove two nuts (7), the washers, and bracket

(10). Insert two bolts (12) into the threaded holes
in order to remove cover (11) and the O-ring seals.
Illustration 177
g01832914
56
Illustration 180
KENR6052-01
g01712258
Illustration 183
g01711679
Illustration 184
g01832914
8. Remove oil screen (13).
Illustration 181
g01712258
1. Install oil screen (13).
4. Position hose assembly (9) and harness assembly

(5). Position bracket (6) and install two washers
and nuts (7). Tighten four nuts (7) to a torque of
35 5 Nm (26 4 lb ft). Repeat the torque until
the cover is pulled into the position and seated.
5. Install fuel filters (8). Position bracket (4) and
install the spacers, the washers, and nuts (3).
6. Position oil filters (1) and install clamps (2).
8. Fill the engine with oil. Refer to Operation and
Illustration 182
g01711680
Note: Check the O-ring seal for wear or for damage.

If necessary, replace the O-ring seal.
2. Remove two bolts (12) from cover (11). Install the
O-ring seal onto cover (12).
3. Position cover (11) on the engine oil pan. Position
bracket (10) and install two washers and nuts (7).
KENR6052-01
57
i02642662
Engine Oil Pan - Remove

SMCS Code: 1302-011
Removal Procedure
Table 32
Required Tools
Tool
Part Number
Part Description
Qty
1U-7505
Transmission Jack
1. Turn the battery disconnect switch to the OFF

position.
2. Turn the fuel supply valve to the OFF position.
NOTICE
Illustration 185
g01852673
Illustration 186
g01459290

products.
mandates.
3. Remove the front and the rear oil drain plugs.
Drain the oil from the engine into a suitable
container for storage or for disposal. Refer to
Operation and Maintenance Manual, Engine Oil
and Filter - Change.
4. Remove bolts (1). Remove bolts (5) and the

flange. Remove tube assemblies (2) and (7).
5. Remove bolts (4) and bolts (8) from engine
mounting brackets (6). Remove bolts (3) from oil
pan assemblies (9).
6. Support the engine mounting brackets with a
suitable lifting device. Position Tooling (A) in the
center of the rear oil pan assembly (9) and lower.
Reposition Tooling (A) in the center of the center
oil pan assembly and lower. The weight of oil pan
assemblies (9) is approximately 101 kg (223 lb).
58
Illustration 187
KENR6052-01
g01833637
7. Disconnect harness assembly (13). Remove nuts

(12) and the washers. Remove elbow (11) and the
O-ring seals. Remove bolts (10). Remove bolts (3)
from oil pan assembly (9).
Illustration 189
g01406662
8. Disconnect harness assembly (16). Remove

bolts (14) and (15) and remove brackets (17).
Remove fuel filters (18) and remove harness
assembly (19). Use Tooling (A) to support oil pan
assembly (9). Remove bolts (3) and lower oil pan
assembly (9). The weight of oil pan assembly (9)
is approximately 116 kg (256 lb).
9. Remove the oil pan gasket.
i02643834
Engine Oil Pan - Disassemble

SMCS Code: 1302-015
Illustration 188
g01853313
Start By:
a. Remove the engine oil screen. Refer to
Disassembly and Assembly, Engine Oil Screen
- Remove and Install.
b. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove.
KENR6052-01
59
2. Install engine oil screen housing (2) into oil pan

assembly (5). Install bolts (1) and the washers.
End By:
a. Install the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Install.
b. Install the engine oil screen. Refer to Disassembly
and Assembly, Engine Oil Screen - Remove and
Install.
i02643872
Engine Oil Pan - Install

SMCS Code: 1302-012
Illustration 190
g01407572
Table 33
Required Tools
1. Remove bolts (1), the washers, and engine oil

screen housing (2) from oil pan assembly (5).
2. Remove bolts (3) and the washers and remove
plate (4) from oil pan assembly (5).
Tool
Part Number
1U-7505
Part Description
Transmission Jack
Qty
1
i02643862
Engine Oil Pan - Assemble

SMCS Code: 1302-016
Assembly Procedure
Illustration 192
Illustration 191
g01407572
1. Install plate (4) into oil pan assembly (5). Install

bolts (3) and the washers.
g01406662
60
Illustration 193
KENR6052-01
g01853313
Illustration 195
g01459290
Illustration 196
g01852673
1. Install the oil pan gasket.

2. Position Tooling (A) under oil pan assembly
(9). The weight of oil pan assembly (9) is
approximately 116 kg (256 lb). Position oil pan
assembly (9) onto the engine cylinder block. Install
bolts (3). Install harness assembly (19). Install fuel
filters (18). Position brackets (17) and install bolts
(14) and (15). Connect harness assembly (16).
4. Locate Tooling (A) under the center of the center

oil pan assembly and raise into position. Install
bolts (3). Locate Tooling (A) under the center of
rear oil pan assemblies(9) and raise into position.
Install bolts (3). The weight of oil pan assemblies
(9) is approximately 101 kg (223 lb).
Illustration 194
g01833637
3. Connect elbow (11) onto oil pan assembly (9).

Install nuts (12) and the washers. Install bolts
(3) into oil pan assembly (9). Install bolts (10).
Connect harness assemblies (13).
5. Position engine mounting brackets (6). Install

bolts (4) and bolts (8). First install bolts (4) and
then tighten bolts (8). Remove the support on the
engine mounting brackets.
Note: If tightening bolts (4) and bolts (8) are done
in reverse order the joint between the pan and the
block could slip.
6. Connect tube assembly (2) and (7). Install bolts
(1). Position the flange and install bolts (5).
8. Turn the fuel supply valve to the ON position.
KENR6052-01
61
9. Turn the battery disconnect switch to the ON

position.
i02644444
Engine Oil Scavenge Pump Remove

SMCS Code: 1312-011
Removal Procedure
Table 34
Required Tools
Tool
Part Number
Part Description
Qty
1U-9744
Floor Jack
Start By:
a. Remove the engine oil pan. Refer to Disassembly
Illustration 198
g01433802
3. Remove bolts (7). Remove elbow (8) and the

O-ring seals from tube assembly (6).
NOTICE
component life.
Illustration 199
Illustration 197
g01433801
1. Remove bolts (4) in order to remove elbow

assembly (5) and the O-ring seals.
2. Remove bolts (3) and the washers in order to
remove clips (2). Remove tubes (1).
g01326650
4. Use Tooling (A) to support engine oil scavenge

pump (10). The weight of engine oil scavenge
pump (10) is approximately 61 kg (134 lb).
Remove bolts (9) and remove engine oil scavenge
pump (10).
62
KENR6052-01
Illustration 201
g01205956
1. Remove bolt (1).

2. Use Tooling (A) to remove gear (2).
g01326651
Illustration 200

cover (12) and gasket (13.). Remove two screens
(14) and (16) and gasket (15) from elbow (17).
i02412825
Engine Oil Scavenge Pump Disassemble

SMCS Code: 1312-015
Table 35
Required Tools
Tool
A
Part
Number
Part Description
Qty
1P-2321
Combination Puller
9S-9155
Spacer
Start By:
a. Remove the engine oil scavenge pump. Refer
to Disassembly and Assembly, Engine Oil
Scavenge Pump - Remove.
NOTICE
component life.
Illustration 202
g00923147
3. Mark body (3) and cover (6) for assembly

purposes.
4. Remove bolts (7) and cover (6).
5. Remove dowels (5) and sleeve bearings (4) from
cover (6).
KENR6052-01
63
g01205955
Illustration 203
Illustration 205
g01205958
Illustration 206
g00604752
6. Remove drive shaft assembly (8) and idler shaft

assembly (9) from body (3).
g01205958
Illustration 204
7. Remove sleeve bearings (10) from body (3).

i02412840
1. Apply clean engine oil to sleeve bearings (10).

Use Tooling (B) to install sleeve bearings (10) to
body (3).
2. Position the joints in sleeve bearings (10) for 45
15 degrees from the center of the bearing bore.
See Item (11) in Illustration 206.
Engine Oil Scavenge Pump Assemble

SMCS Code: 1312-016
Assembly Procedure
Table 36
Required Tools
Tool
Part
Number
1P-0510
Part Description
Driver Group
Qty
1
Illustration 207
NOTICE
component life.
g01206054
3. Install sleeve bearings (10) to a depth of

1.5 0.5 mm (0.06 0.02 inch) in body (3). See
Item (12) in Illustration 207.
64
KENR6052-01
After installing sleeve bearings (10), measure

the inner diameter of sleeve bearings (10). The
inner diameter must be 31.837 0.070 mm
(1.2534 0.0028 inch).
Illustration 208
Illustration 210
g01206142
Illustration 211
g01206144
g01205955
4. Apply clean engine oil to idler shaft assembly (9)

and drive shaft assembly (8). Install idler shaft
assembly (9) and drive shaft assembly (8) into
body (3).
7. Align the marks on cover (6) and body (3) and

position cover (6). Install bolts (7).
8. Install gear (2).
Illustration 209
g01206056
5. Apply clean engine oil to sleeve bearings (4). Use

Tooling (B) to install sleeve bearings (4) in cover
(6). Position the joints in sleeve bearings (4) for 45
15 degrees from the center of the bearing bore.
Install sleeve bearings (4) to a depth of
1.5 0.5 mm (0.06 0.02 inch). See Item (14)
in Illustration 209.
After installing sleeve bearings (4), measure
the inner diameter of sleeve bearings (4).
The diameter must be 31.837 0.070 mm
(1.2534 0.0028 inch).
6. Install dowels (5) into cover (6). Install dowels
(5) so that dowels (5) protrude 6.4 0.5 mm
(0.25 0.02 inch) from the surface of cover (6).
Tap on gear (2) in order to seat the taper onto the

shaft. Install bolt (1). Tighten bolt (1) to a torque of
100 20 Nm (75 15 lb ft). Repeat this procedure
until the torque does not change.
End By:
a. Install the engine oil scavenge pump. Refer
Scavenge Pump - Install.
KENR6052-01
65
i02644715
Engine Oil Scavenge Pump Install

SMCS Code: 1312-012
Table 37
Required Tools
Tool
Part Number
Part Description
Qty
1U-9744
Floor Jack
NOTICE
component life.
Illustration 213
g01326650
3. Use Tooling (A) to support engine oil scavenge

pump (10). The weight of oil scavenge pump (10)
is approximately 61 kg (134 lb). Raise into position
on the engine cylinder block and install bolts (9).
Illustration 212
g01326651
1. Position gasket (15) and two screens (16) and

(14) onto elbow (17).
2. Position gasket (13) and install cover (12). Install
bolts (11) and the washers.
Illustration 214
g01433802
4. Inspect the O-ring seals before installing on

tube assembly (6). Obtain new O-ring seals,
if necessary. Install tube assembly (6) into the
engine oil scavenge pump. Install elbow (8) and
install bolts (7).
66
KENR6052-01
i02644848
Crankcase Breather - Remove

and Install
SMCS Code: 1317-010
Removal Procedure
Illustration 215
g01433801
5. Install tubes (1). Position clips (2) and install bolts

(3).
6. Inspect the O-ring seals before installing and
obtain new O-ring seals, if necessary. Install the
O-ring seals on the tube assemblies. Place elbow
(5) onto the tube assemblies. Install bolts (4).
End By:
a. Install the engine oil pan. Refer to Disassembly
Illustration 216
g01834773
1. Remove bolts (7) and remove clips (6). Loosen

hose clamp (2) and remove elbow (4) and tube (8).
2. Remove bolts (5) and remove clamps (3). Remove
crankcase breather (1). Repeat for the opposite
side.
Illustration 217
g01834773
KENR6052-01
67
1. Position crankcase breather (1). Position clamps

(3) and install bolts (5).
2. Connect elbow (4) and tube (8). Tighten hose

clamp (2). Position clips (6) and install bolts (7).
Repeat for the opposite side.
i03146340
Valve Cover - Remove and

Install
SMCS Code: 1107-010
Removal Procedure
Illustration 220
g01619004
1. Install a new seal (3) onto valve cover (2).
Illustration 218
g01619003
1. Remove five bolts (1) and the washers. Remove

valve cover (2).
Illustration 221
g01619003
2. Position valve cover (2). Install the washers and

five bolts (1). Tighten bolts (1) to a torque of
28 7 Nm (21 5 lb ft).
3. Repeat Steps 1 and 2 for the remaining valve
covers.
Illustration 219
g01619004
2. Remove seal (3) from valve cover (2).

covers.
68
KENR6052-01
i03474986
Rocker Shaft and Push Rods Remove

SMCS Code: 1102-011
i03515048
Rocker Shaft - Disassemble

SMCS Code: 1102-015
Removal Procedure
Table 38
Required Tools
Start By:
a. Remove the valve cover. Refer to Disassembly
and Assembly, Valve Cover - Remove and
Install.
Tool
Part Number
1P-0510
Part Description
Driver Gp
Qty
1
Start By:
a. Remove the rocker shaft. Refer to Disassembly
and Assembly, Rocker Shaft and Push Rod Remove.
Illustration 222
g01848037
1. Remove bolts (1). Remove rocker shaft assembly

(2).
Illustration 224
g01846479
1. Note the orientation of rocker arm assembly (1)

for assembly purposes.
Note:
Illustration 223
g01848038
2. Remove pushrods (3). Remove bridges (4).
Illustration 225
g01846480
KENR6052-01
69
2. Remove rocker arms (2), and (8), and shaft (5)

from support assembly (7).
3. Remove rocker arms (2) and (8) from shaft (5).
4. Use Tooling (A) and remove bushing (6) from
rocker arm (2) and (8).
5. Remove nut (3) and adjusting screw (4).
i03515422
Rocker Shaft - Assemble

SMCS Code: 1102-016
Illustration 227
Assembly Procedure
g01846479
4. Ensure that rocker arm assembly (1) is correctly

oriented in order to prevent damage.
Table 39
End By:
Required Tools
Tool
Part Number
1P-0510
Part Description
Driver Gp
Qty
1
a. Install the rocker shaft. Refer to Disassembly and

Assembly, Rocker Shaft and Push Rod - Install.
i03671543
Rocker Shaft and Push Rods

- Install
SMCS Code: 1102-012
Illustration 226
g01846480
1. Install adjusting screw (4) and nut (3).

Illustration 228
2. Use Tooling (A) and install bushing (6) into rocker

arm (2) and (8). Make sure that the oil holes in
bushing (6) are aligned with the oil holes in rocker
arm (2) and (8). The oil holes must be aligned in
the exact position.
3. Install rocker arms (2) and (8) on shaft (5).
Position rocker arms (2), and (8), and shaft (5)
onto support assembly (7).
g01848038
70
KENR6052-01
i02408869
Valve Lifter - Remove

SMCS Code: 1209-011
Removal Procedure
Table 40
Required Tools
Illustration 229
g01949432
1. Install bridges (4) on the cylinder head. Position

the round pocket toward the outside of the engine.
Lubricate pushrods (3) with clean engine oil. Install
pushrods (3). Seat pushrods (3) in the lifter cups.
Note: Ensure that the pushrods are seated in the
bores. Use a flashlight in order to ensure that the
pushrods are in the lifter cups.
Tool
Part Number
Part Description
Qty
3E-3879
Eyebolt
Start By:
a. Remove the rocker shaft and pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrods - Remove.
b. Remove the exhaust manifolds. Refer to
Disassembly and Assembly, Exhaust Manifold
NOTICE
component life.
Illustration 230
g01848037
2. Position rocker shaft assembly (2) in the dowel

holes. Install bolts (1). Tighten bolts (1) to a torque
of 200 30 Nm (147 22 lb ft).
3. Adjust the valve lash. Refer to Testing and
Adjusting, Engine Valve Lash - Inspect/Adjust.
4. Lubricate bridges (4) and the pockets with clean
engine oil.
End By:
a. Install the valve cover. Refer to Disassembly and
Assembly, Valve Cover - Remove and Install.
Illustration 231
g01203661

onto valve lifter (1). Remove bolts (2). Remove
valve lifter (1).
KENR6052-01
Illustration 232
71
g01204525
Illustration 234
2. Remove levers (4) from shaft (5). Remove thrust

washer (6) from shaft (5).
2. Remove integral seal (3).

lifters.
i02410099
i02410168
Valve Lifter - Assemble
Valve Lifter - Disassemble
SMCS Code: 1209-016
SMCS Code: 1209-015
NOTICE
Start By:
a. Remove the valve lifter. Refer to Disassembly and
Assembly, Valve Lifter - Remove.
Illustration 233
g01204412
g01204408
1. Remove bolts (1). Remove shaft assembly (2)

from housing (3).

component life.
Illustration 235
g01204412
1. Install thrust washer (6) onto shaft (5). Install

levers (4) onto shaft (5).
72
KENR6052-01
1. Install integral seal (3).
g01204408
Illustration 236
2. Install shaft assembly (2) into housing (3).

Install bolts (1). Tighten bolts (1) to a torque of
55 10 Nm (41 7 lb ft).
g01203661
Illustration 238
End By:

onto valve lifter (1). Position valve lifter (1) onto
the engine. Install bolts (2). Tighten bolts (2) to a
a. Install the valve lifter. Refer to Disassembly and

Assembly, Valve Lifter - Install.

lifters.
i02409468
Valve Lifter - Install
End By:
a. Install the exhaust manifolds. Refer to
Disassembly and Assembly, Exhaust Manifold
SMCS Code: 1209-012
b. Install the rocker shaft and pushrods. Refer to

Pushrods - Install.
Table 41
Required Tools
Tool
Part Number
Part Description
Qty
3E-3879
Eyebolt
i03713115
Electronic Unit Injector Remove
NOTICE
SMCS Code: 1290-011

component life.
Removal Procedure
Table 42
Required Tools
Tool
Part
Number
Part Description
Qty
5F-4764
Prybar
339-9352
Inj. Sys Cap Kit
265-2256
Wipers
Start By:
Illustration 237
g01204525
a. Remove the valve cover. Refer to Disassembly

and Assembly, Valve Cover - Remove and
Install.
KENR6052-01
73
NOTICE
products.
mandates.
Illustration 240
g01285666
2. Apply clean engine oil to Area (X). Repeat for the

opposite collar. Remove bolts (4) and bolts (6).
Remove tube assembly (5).
NOTICE
component life.

fittings, ports, and any openings in the fuel system in
Illustration 241
g01999931
3. Disconnect harness assembly (7) from electric

unit injector (8). Remove bolt (9) and the washer.
4. Place an identification mark on electronic unit
injector (8) for installation purposes. Each
electronic unit injector must be reinstalled in the
original location. Use Tooling (A) to pry electronic
unit injector (8) out by the retaining collar.
Illustration 239
g01285474

74
KENR6052-01
g01410032
Illustration 242
5. Check O-ring seals (10) and (11) on electronic

unit injector (8).
Illustration 243
g01410032
1. If necessary, install new O-ring seals (10) and

(11) onto electronic unit injector (8). Apply clean
engine oil to O-ring seals (10) and (11).
i03714060
Electronic Unit Injector - Install

SMCS Code: 1290-012
Table 43
Required Tools
Tool
B
C
Part Number
Part Description
Qty
339-9352
Inj. Sys Cap Kit
265-2256
Wipers
312-3204
Brush

NOTICE
component life.
Illustration 244
g01999931
2. Check the cleanliness of the sealing surface for

the unit injector in the cylinder head. If necessary,
use Tooling (C) to clean the sealing cone on the
unit injector.
3. Install electronic unit injector (8). Tighten bolt (9)
to a torque of 60 12 Nm (44 9 lb ft).
4. Remove bolt (9). Hand tighten bolt (9) and the
washer. Tighten bolt (9) to a torque of 10 Nm
(7.5 lb ft). Connect harness assembly (7) onto
electronic unit injector (8).
KENR6052-01
Illustration 245
75
g01285666
g01285474
Illustration 247

O-ring seals on both ends of tube assembly (1).
Install tube assembly (1). Install the washer and
bolt (3).
End By:
a. Install the valve cover. Refer to Disassembly and
Assembly, Valve Cover - Remove and Install.
i03520540
Illustration 246
g01285695
5. Apply clean engine oil to Area (X). Repeat for the

opposite collar. Apply clean engine oil to the ends
of tube assembly (5). Install tube assembly (5).
Install bolts (4) and bolts (6) hand tight. Evenly
Evenly tighten bolts (6) to a torque of 20 Nm
(15 lb ft).
degrees at a time.
6. Tighten nut (9) to a torque of 100 2 Nm
(74 1 lb ft). Evenly tighten bolts (4) to a torque
of 40 Nm (30 lb ft). Evenly tighten bolts (6) to a
degrees at a time.
Electronic Unit Injector Sleeve

- Remove
SMCS Code: 1713-011
Removal Procedure
Table 44
Required Tools
Tool
Part Number
333-0759
Part Description
Qty
Injector Sleeve
Shaft
Start By:
a. Remove the electronic unit injector. Refer to
Disassembly and Assembly, Electronic Unit
Injector - Remove.
b. Remove the rocker shaft and pushrods. Refer to
Push Rods - Remove.
76
KENR6052-01
i03520800
NOTICE
products.
mandates.
Electronic Unit Injector Sleeve

- Install
SMCS Code: 1713-012
Table 45
Required Tools
Tool
Part Number
333-0759
Injector Sleeve Shaft
4C-9506
Retaining Compound
g01850908
2. Install the puller of Tooling (A) into the electronic

unit injector sleeve. Hand tighten the puller.
Illustration 249
g01850913
3. Install Tooling (A) onto the cylinder head. Refer to

Illustration 249. Tighten the nut of Tooling (A) in
order to remove the electronic unit injector sleeve.
Qty
1. Thoroughly clean the bore in the cylinder for the

electronic unit injector sleeve.
Illustration 250
Illustration 248
Part Description
g01228702
2. Install new O-ring seals (1) on electronic unit

injector sleeve (2). Apply clean engine oil on
O-ring seals (1). Apply Tooling (B) to Area (X).
Illustration 251
g01850908
3. Install the puller of Tooling (A) into electronic unit

injector sleeve (2). Tighten the collar of Tooling (A)
against electronic unit injector sleeve (2).
KENR6052-01
77
NOTICE
products.
g01228701
Illustration 252
4. Install electronic unit injector sleeve (2) and

Tooling (A) into cylinder head (3). Place the driver
of Tooling (A) over puller of Tooling (A). Use a
suitable hammer and install electronic unit injector
sleeve (2). Install electronic unit injector sleeve (2)
until electronic unit injector sleeve (2) is seated in
cylinder head (3).
End By:
a. Install the rocker shaft and pushrods. Refer to
Push Rods - Install.
b. Install the electronic unit injector. Refer to
Injector - Install.
i03330642
Cylinder Head - Remove

mandates.
NOTICE
component life.
Note: Use Tooling (B) to prevent contamination.
Cleanliness is an important factor. Before you
begin the disassembly procedure, the exterior of
the components should be thoroughly cleaned.
This will help to prevent dirt from entering the
internal mechanism. Precision components can
be damaged by contaminants or by dirt. Perform
disassembly procedures on a clean work surface.
Keep components covered and protected at all times.
SMCS Code: 1100-011
Removal Procedure
Table 46
Required Tools
Tool
Part Number
138-7573
Link Bracket
339-9352
Inj. Sys Cap Kit
265-2256
Wipers
Part Description
Qty
Start By:
a. Remove the rocker shaft and pushrods. Refer to
Push Rods - Remove.
Illustration 253
g01835153
78
KENR6052-01
2. Remove bolts (1). Disconnect exhaust manifold

(2). Remove bolts (9). Disconnect inlet manifold
(10).
i03647221
Cylinder Head - Install

SMCS Code: 1100-012

4. Remove bolts (12) and bolts (11). Remove tube
assembly (8).
Note: Exercise care in removing the cylinder head
and the gasket in order to avoid contamination of oil
supply holes in the cylinder block.
onto cylinder head (3). Cylinder head (3) weighs
approximately 68 kg (150 lb). Remove bolts
(4). Remove cylinder head (3) from the engine.
Position cylinder head (3) onto suitable cribbing
in order to prevent damage to the electronic unit
injector.
Note: The positioning dowels need to remain in the
cylinder block. Remove the dowels if the dowels
remain in the cylinder head. Install the new dowels in
the cylinder block before installing the cylinder head.
Table 47
Required Tools
Tool
Part
Number
138-7573
Link Bracket
339-9352
Inj. Sys Cap Kit
265-2256
Wipers
1P-0808
Multipurpose
Grease
312-2840
Socket
g01202717
6. Remove gasket (13) from the cylinder block.

Remove fire ring (14).
Qty

prevent contamination. Cleanliness is an important
factor. Before assembly, thoroughly clean all parts
in cleaning fluid. Allow the parts to air dry. Do not
use wiping cloths or rags to dry parts. Lint may be
deposited on the parts which may cause trouble.
Inspect all parts. If any parts are worn or damaged,
use new parts for replacement. Dirt and other
contaminants can damage the precision component.
Perform assembly procedures on a clean work
surface. Keep components covered and protected
at all times.
Illustration 255
Illustration 254
Part Description
g01202717
1. Inspect fire ring (14) for damage and install new,

if necessary. Install fire ring (14). Install a new
gasket (13) onto the cylinder block.
KENR6052-01
Illustration 256
79
g01835773
Illustration 258
g01835795
Illustration 259
g01285695

onto cylinder head (3). Cylinder head (3) weighs
approximately 68 kg (150 lb). Position cylinder
head (3) onto the cylinder block. Lubricate the
threads of bolts (4) with oil. Install bolts (4).
4. Apply clean engine oil to Area (X). Repeat for

the opposite collar. Apply Tooling (C) to the ends
of tube assembly (8). Install tube assembly (8).
Install bolts (12) and bolts (11) hand tight. Evenly
Evenly tighten bolts (11) to a torque of 20 Nm
(15 lb ft). Evenly tighten bolts (12) to a torque of
40 Nm (30 lb ft). Evenly tighten bolts (11) to a
Illustration 257
g01957702
3. Tighten bolts (4) in the numerical sequence to a

torque of 30 5 Nm (22 7 lb ft). Use Tooling
(D) to tighten bolts (4) in the numerical sequence
Tighten bolts (4) again in the numerical sequence
Tighten bolts (4) in the numerical sequence for an
additional 175 to 185 degrees.

O-ring seals on both ends of the tube assembly
(5). Install tube assembly (5). Install the washer
and bolt (7).
6. Position inlet manifold (10). Install bolts (9).
Position exhaust manifold (2). Install bolts (1).
80
KENR6052-01
End By:
a. Install the rocker shaft and pushrods. Refer to
i03520962
Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010
Removal Procedure
Illustration 261
g01207146
Table 48
Required Tools
Tool
Part Number
333-0758
Part Description
Valve Spring
Compressor
Qty
1

Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.

1. Install Tooling (A) into the hole for the electronic
unit injector. Refer to Illustration 261.
NOTICE
component life.
Illustration 262
Illustration 260
g01206603
g01851274
2. Install the plate of Tooling (A) onto the valve

springs. Refer to Illustration 262. Install the nut
onto the stud. Tighten the nut in order to compress
valve springs (2). Remove retainer locks (1).
KENR6052-01
81
g01298522
Illustration 263
3. Remove Tooling (A). Remove rotocoil (3), outer

spring (4), and inner spring (5).
4. Repeat Steps 1 through 3 for the remaining valve
springs.
333-0758
Part Description

springs.
a. Install the cylinder head. Refer to Disassembly

and Assembly, Cylinder Head - Install.
Required Tools
Part Number
2. Use Tooling (A) in order to compress valve springs

(2). Install retainer locks (1). Release the tension
on valve springs (2). Remove Tooling (A).
End By:
Table 49
Tool
g01851274
Illustration 265
Qty
Valve Spring
Compressor
i03520944
Inlet and Exhaust Valves Remove and Install

SMCS Code: 1105-010
Removal Procedure
Table 50
Required Tools
Illustration 264
g01298522

1. Install inner spring (5), outer spring (4), and
rotocoil (3).
Tool
Part Number
333-0758
Part Description
Qty
Valve Spring
Compressor
Start By:
a. Remove the electronic unit injector. Refer to
Injector - Remove.
b. Remove the cylinder head. Refer to Disassembly
NOTICE
component life.
82
KENR6052-01

Illustration 266
g01206603
g01206605
Illustration 269
Illustration 267
g01207146


spring (4), inner spring (5), valve seal (6), retainer
(7), and valve (8).
Table 51
Required Tools
Illustration 268
Tool
Part Number
333-0758
Part Description
Valve Spring
Compressor
Qty
1
g01851274

Illustration 270
g01206605
KENR6052-01
83
1. Install valve (8), retainer (7), valve seal (6), inner

spring (5), outer spring (4), and rotocoil (3).
Illustration 271
g01206603

on valve springs (2). Remove Tooling (A). Install
a screwdriver into the hole for the injector. Slowly
rotate the engine until the piston is approximately
25 mm (1.00 inch) below top dead center. Lightly
strike the tops of the valves with a soft faced
hammer in order to ensure that retainer locks (1)
are properly seated.
End By:
b. Install the electronic unit injector. Refer to
Injector - Install.
i02413949
Inlet and Exhaust Valve Guides

- Remove and Install
SMCS Code: 1104-010
Removal Procedure
Illustration 272
g01228542
Table 52
Required Tools
Tool
Part Number
283-0052
Part Description
Valve guide driver
Qty
1
Start By:
a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, Inlet and Exhaust
Valves - Remove and Install.
NOTICE
Illustration 273
g01851274

component life.
84
KENR6052-01
i02414037
Inlet and Exhaust Valve Seat

Inserts - Remove and Install
SMCS Code: 1103-010
Removal Procedure
Table 54
Required Tools
g01206606
Illustration 274
1. Turn over the cylinder head. Use Tooling (A) and a

suitable hammer in order to remove valve guides
(1) from the cylinder head.
Table 53
Part Number
166-7441
Part Description
Valve Seat
Extractor Tool
Tool
Part Number
283-0052
Valve guide driver
284-1503
Collar
Start By:
a. Remove the inlet and exhaust valves. Refer to
Qty

component life.
g01206653
Illustration 276
Illustration 275
Qty
NOTICE
Required Tools
Part Description
Tool
g01211260
1. Coat the outside of the valve guides with clean oil

prior to installation. Use Tooling (A), Tooling (B),
and a suitable hammer in order to install valve
guides (1) into the cylinder head. Valve guide (1)
must extend 42.0 0.50 mm (1.65 0.020 inch)
above the surface of the cylinder head.
1. Turn over the cylinder head. Use Tooling (A) in

order to remove valve seats (1) from the cylinder
head.
Table 55
Required Tools
End By:
a. Install the inlet and exhaust valves. Refer to
Tool
Part Number
1P-0510
Part Description
Driver Gp
Qty
1
KENR6052-01
85
g01206654
Illustration 277
Illustration 278
g01206603
Illustration 279
g01207146
1. Lower the temperature of valve seats (1). Use

Tooling (B) and a suitable hammer in order to
install valve seats (1) into the cylinder head.
End By:
a. Install the inlet and exhaust valves. Refer to
i03520840
Inlet Valve Seals - Remove and

Install

SMCS Code: 1104-010-SA
Removal Procedure
Table 56
Required Tools
Tool
Part Number
333-0758
Part Description
Valve Spring
Compressor
Qty
1
Start By:
NOTICE
component life.
Illustration 280
g01851274

86
KENR6052-01

1. Install a new valve seal (6). Install inner spring (5),

outer spring (4), and rotocoil (3).
Illustration 283
g01206603
Illustration 284
g01228542
Illustration 285
g01851274
g01298551
Illustration 281

spring (4), and inner spring (5). Remove valve
seal (6).
seals.
Table 57
Required Tools
Tool
Part Number
333-0758
Illustration 282
Part Description
Valve Spring
Compressor
Qty
1
g01298551


on valve springs (2). Remove Tooling (A).
seals.
KENR6052-01
87
End By:
i02645131
Front Drive Housing - Remove

and Install
SMCS Code: 1151-010
Removal Procedure
Table 58
Required Tools
Tool
Part Number
138-7574
Part Description
Link Bracket
Qty
2
Start By:
Illustration 286
g01459456
a. Remove the electronic control module (engine).

Refer to Disassembly and Assembly, Electronic
Control Module (Engine) - Remove and Install.
1. Remove mounting assemblies (2). Use Tooling

(A) and a suitable lifting device to remove
mounting assemblies (2). The weight of mounting
assemblies (2) is approximately 207 kg (457 lb).
b. Remove the engine trunnion. Refer to Disassembly

and Assembly, Engine Trunnion - Remove and
Install.
2. Remove bracket assembly (5). Disconnect clamp

assembly (3) and remove tube assembly (4) from
front drive housing (1).
c. Remove the turbochargers. Refer to Disassembly

and Assembly, Turbocharger - Remove.
d. Remove the idler gears. Refer to Disassembly
and Assembly, Idler Gears (Front) - Remove and
Install.
e. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, Crankshaft Front
Seal - Remove.
Illustration 287
g01459588
3. Remove bolts (8), elbow (9), and the O-ring seals.

4. Remove bolts (6), cover (7), and the O-ring seal.
5. Remove bolts (10), covers (11), and the O-ring
seals from front drive housing (1).
88
KENR6052-01
Table 59
Required Tools
Illustration 288
Tool
Part Number
Part Description
Qty
138-7574
Link Bracket
1U-8846
Gasket Sealant
g01327207

onto front drive housing (1). The weight of front
drive housing (1) is approximately 363 kg (800 lb).
Remove bolts (12) and (13). Remove front drive
housing (1).
Illustration 290
g01327262

1. Apply Tooling (B) to the mating surface of front
drive housing (1). Install O-ring seals (14) and
(15).
Illustration 289
g01327262
7. Remove O-ring seals (14) and (15) from front

drive housing (1).
Illustration 291
g01327207
KENR6052-01
89

onto front drive housing (1). The weight of front
drive housing (1) is approximately 363 kg (800 lb).
Install front drive housing (1). Install bolts (12).
Install bolts (13).
7. Use Tooling (A) and a suitable lifting device on

mounting assemblies (2). Position mounting
assemblies (2) on top of front drive housing
(1). The weight of mounting assemblies (2) is
End By:
a. Install the crankshaft front seal. Refer to
Disassembly and Assembly, Crankshaft Front
Seal - Install.
b. Install the idler gears. Refer to Disassembly and
Assembly, Idler Gears (Front) - Remove and
Install.
c. Install the turbochargers. Refer to Disassembly
and Assembly, Turbocharger - Install.
d. Install the engine trunnion. Refer to Disassembly
and Assembly, Engine Trunnion - Remove and
Install.
e. Install the electronic control module (engine).
Refer to Disassembly and Assembly, Electronic
Control Module (Engine) - Remove and Install.
Illustration 292
g01459588
3. Position covers (11) and the O-ring seal on front

drive housing (1). Install bolts (10).
4. Position cover (7) and the O-ring seal. Install bolts
(6).
5. Position elbow (9) and the O-ring seals. Install
bolts (8).
i02645831
Vibration Damper - Remove

and Install
SMCS Code: 1205-010
Removal Procedure
Table 60
Required Tools
Illustration 293
g01459456
6. Position tube assembly (4). Connect clamp

assembly (3). Install bracket assembly (5) to front
drive housing (1).
Tool
Part Number
323-4712
Part Description
Guide Bolt
M24-2 by 500 mm
Qty
2
90
KENR6052-01
Table 61
Required Tools
Illustration 294
Tool
Part Number
323-4712
Part Description
Guide Bolt
M24-2 by 500 mm
Qty
2
g01327453
1. Remove two bolts (2) from vibration damper (1).

2. Install Tooling (A). Remove remaining bolts (2).
Illustration 296
g01327454
1. Attach a suitable lifting device onto vibration

damper (1). The weight of vibration damper (1)
is approximately 137 kg (302 lb). Install Tooling
(A). Position vibration damper (1) onto Tooling (A).
Slide vibration damper (1) on Tooling (A). Remove
the suitable lifting device.
Illustration 295
g01327454
3. Attach a suitable lifting device onto vibration

damper (1). The weight of vibration damper (1) is
4. Slide vibration damper (1) to the end of Tooling
(A). Remove vibration damper (1).
Illustration 297
g01327453
2. Position vibration damper (1). Install bolts (2).

Remove Tooling (A).
KENR6052-01
91
3. Install remaining bolts (2). Tighten bolts (2) to a

i02650798
Crankshaft Front Seal Remove

SMCS Code: 1160-011
Removal Procedure
Table 62
Required Tools
Tool
Part Number
Part Description
Qty
1U-5593
Drill Bit
1U-7600
Slide Hammer
Puller Gp
1
g01331272
Illustration 299
Start By:
a. Remove the vibration damper. Refer to
Disassembly and Assembly, Vibration Damper
- Remove and Install .
1. Use Tooling (A) to drill three evenly spaced holes
in the crankshaft front seal.
4. Use Tooling (B) in order to remove the inner half

of crankshaft front seal (1).
i02650811
Crankshaft Front Seal - Install

SMCS Code: 1160-012
Table 63
Required Tools
Tool
Part Number
250-4587
Illustration 298
g01331272
2. Use Tooling (B) in order to remove the outer half

of crankshaft front seal (1).
in the crankshaft front seal.
Part Description
Qty
Installer
Nut
250-4586
Locator
258-0933
Bolt
9S-8858
92
KENR6052-01
Illustration 301
g01842656
1. Attach a suitable lifting device and Tooling (C)

to adapter (1). The weight of adapter (1) is
approximately 89 kg (196 lb). Remove bolts (2)
and the washers. Remove adapter (1).
g01331288
Illustration 300
1. Use Tooling (C) to install crankshaft front seal (1).

End By:
a. Install the vibration damper. Refer to Disassembly
and Assembly, Vibration Damper - Remove and
Install.
i02646094
Flywheel - Remove and Install

g01327607
SMCS Code: 1156-010
Illustration 302
Removal Procedure
2. Remove two bolts (4) from flywheel (3). Install

Tooling (A).
Table 64
Required Tools
Tool
Part Number
Part Description
Qty
323-4712
Guide Bolt
M24 - 2 by 500 mm
140-7742
Protective Sleeve
138-7575
Link Bracket
Illustration 303
g01327608
3. Attach a suitable lifting device and Tooling (B)

to flywheel (3). The weight of flywheel (3) is
approximately 216 kg (476 lb). Remove remaining
bolts (4). Slide flywheel (3) on Tooling (A). Remove
flywheel (3).
KENR6052-01
93
Table 65
Required Tools
Tool
Part Number
Part Description
Qty
323-4712
Guide Bolt
M24 - 2 by 500 mm
140-7742
Protective Sleeve
138-7575
Link Bracket
g01202287
Illustration 306
4. Remove Tooling (A) and install remaining bolts

(4). Tighten bolts (4) to a torque of 1100 60 Nm
(811 44 lb ft).
Illustration 304
g01327608
1. Install Tooling (A) into the crankshaft.

2. Use Tooling (B) and a suitable lifting device in
order to position flywheel (3) onto Tooling (A). The
weight of flywheel (3) is approximately 216 kg
(476 lb).
g01842656
Illustration 307
5. Use Tooling (C) and a suitable lifting device

in order to position adapter (1). The weight of
adapter (1) is approximately 89 kg (196 lb). Install
the washers and bolts (2). Tighten bolts (2) to a
i02650843
Crankshaft Rear Seal - Remove

SMCS Code: 1161-011
Illustration 305
g01327607
3. Remove the suitable lifting device and slide

flywheel (3) on Tooling (A). Lubricate the threads
of bolts (4) with oil. Install bolts (4).
Removal Procedure
Table 66
Required Tools
Tool
Part Number
Part Description
Qty
1U-5593
Drill Bit
1U-7600
Slide Hammer
Puller Gp
94
KENR6052-01
Start By:
i02650861
a. Remove the flywheel. Refer to Disassembly and

Assembly, Flywheel - Remove and Install.
in the crankshaft rear seal.
Crankshaft Rear Seal - Install

SMCS Code: 1161-012
Table 67
Required Tools
Tool
Part Number
250-4587
Illustration 308
Part Description
Qty
Installer
Nut
250-4586
Locator
322-2078
Bolt
9S-8858
g01331317
2. Use Tooling (B) in order to remove the outer half

of rear crankshaft seal (1).
in the crankshaft rear seal.
Illustration 310
g01331334
1. Use Tooling (C) to install crankshaft rear seal (1).

End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove and Install.
Illustration 309
g01331317
4. Use Tooling (B) in order to remove the inner half

of rear crankshaft seal (1).
KENR6052-01
95
i02646526
Flywheel Housing - Remove

SMCS Code: 1157-011
Removal Procedure
Table 68
Required Tools
Tool
Part Number
Part
Description
Qty
138-7575
Link Bracket
Start By:
a. Remove the air starting Motor. Refer to
Disassembly and Assembly, Air Starting Motor
- Remove.
g01328213
b. Remove the crankcase breather. Refer to

Disassembly and Assembly, Crankcase Breather
Illustration 311
NOTICE
5. Remove bolts (2) and remove cover (3). Remove

bolts (6) and remove cover (7) from flywheel
housing (1).
4. Disconnect the clamps and remove tube

assemblies (4) and (5).
6. Remove bolts (8) and the washers. Remove plate

assembly (9).

products.
mandates.
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
2. Use the timing pins in order to properly time the
engine. Refer to Testing and Adjusting, Camshaft
Timing. Refer to Testing and Adjusting, Finding
the Top Center Position for the No. 1 Piston.
3. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, Crankshaft Rear
Seal - Remove.
Illustration 312
g01328214
7. Remove bolts (10) and plate (11). Remove gear

(12) from flywheel housing (1).
96
Illustration 313
KENR6052-01
g01328355
8. Disconnect harness assembly (14). Remove bolts

(13). Remove cover (15).
g01328215
Illustration 316

onto flywheel housing (1). The weight of flywheel
housing (1) is approximately 421 kg (927 lb).
Apply slight lifting tension on flywheel housing (1).
12. Remove bolts (20) and (21). Remove flywheel
housing (1).
i02647169
Illustration 314
g01328357
9. Disconnect harness assembly (18). Remove bolt

(16). Remove crankshaft position sensor (17).
Flywheel Housing - Install

SMCS Code: 1157-012
Table 69
Required Tools
Illustration 315
g01328359
10. Remove bolts (19) that connect the oil pan to

flywheel housing (1).
Tool
Part Number
Part Description
Qty
138-7575
Link Bracket
1U-8846
Gasket Sealant
KENR6052-01
97
Illustration 319
g01328357
3. Install crankshaft position sensor (17). Install bolt

(16). Connect harness assembly (18).
Illustration 317
g01328215

onto flywheel housing (1). The weight of flywheel
housing (1) is approximately 421 kg (927 lb).
Apply Tooling (B) to the mating surface of flywheel
housing (1). Position flywheel housing (1). Install
bolts (20) and (21).
Illustration 320
g01328355
4. Position cover (15). Install bolts (13). Connect

Illustration 318
g01328359
2. Install bolts (19) that connect the oil pan to

flywheel housing (1).
Illustration 321
g01328214
5. Install gear (12). Install plate (11) and bolts (10)

to flywheel housing (1).
98
KENR6052-01
Start By:
a. Remove the engine oil and water pump drive.
Refer to Disassembly and Assembly, Engine Oil
and Water Pump Drive - Remove.
b. Remove the fuel and auxiliary water pump drive.
Refer to Disassembly and Assembly, Fuel and
Auxiliary Water Pump Drive - Remove.
c. Remove the vibration damper. Refer to
g01328213
Illustration 322
6. Position plate assembly (9). Install bolts (8) and

the washers.
7. Position cover (7). Install bolts (6). Position cover
(3) on flywheel housing (1). Install bolts (2).
8. Install tube assemblies (4) and (5) and connect
the clamps.
End By:
a. Install the crankcase breather. Refer to
Disassembly and Assembly, Crankcase Breather
b. Install the air starting motor. Refer to Disassembly
and Assembly, Air Starting Motor - Install.
Illustration 323
g01596074
1. Remove bolts (1). Remove cover (2). Remove

bolts (3). Remove cover (4). Remove bolts (5).
Remove bolts (6).
c. Install the crankshaft rear seal. Refer to

Disassembly and Assembly, Crankshaft Rear
Seal - Install.
i03120063
Idler Gears (Front) - Remove

and Install
SMCS Code: 1206-010
Removal Procedure
Table 70
Required Tools
Tool
Part Number
Part Description
Qty
1P-0520
Driver Gp
1
Illustration 324
g01596077
KENR6052-01
99
g01229252
Illustration 325
2. Support idler gear (7). Remove pin (8). Remove

the O-ring seal from pin (8). Lower idler gear (7)
to the bottom of the front drive housing. Remove
idler gear (7) from the back side of the front drive
housing.
Illustration 327
g01229253

install bearing (9) into gear (7).
Illustration 328
g01229252
Illustration 329
g01596077
g01229253
Illustration 326

remove bearing (9) from gear (7).
Table 71
Required Tools
Tool
Part Number
Part Description
Qty
1P-0520
Driver Gp
2. Position idler gear (7) into the back side of the

front drive housing. Raise idler gear (7) from the
bottom of the front drive housing into position.
Install a new O-ring seal onto pin (8). Install pin (8)
into idler gear (7).
100
KENR6052-01
Illustration 331
g01209637
1. Remove bolts (1). Remove plate (2). Remove

gear (3).
Illustration 330
g01596074
4. Install bolts (6). Install bolts (5). Install cover (4).

Install bolts (3). Install cover (2). Install bolts (1).
End By:
and Assembly, Vibration Damper - Remove and
Install.
b. Install the fuel and auxiliary water pump drive.
Refer to Disassembly and Assembly, Fuel and
Auxiliary Water Pump Drive - Install.
Illustration 332
g01209639
2. Remove bearing (4).
c. Install the engine oil and water pump drive. Refer

to Disassembly and Assembly, Engine Oil and
Water Pump Drive - Install.
i02421071
Gear Group (Rear) - Remove

SMCS Code: 1206-011; 1212-011
Removal Procedure
Start By:
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing
- Remove.
Illustration 333
g01209641
3. Remove bolts (5). Remove shaft assembly (6).
KENR6052-01
101
g01209643
Illustration 334
4. Remove bolts (7). Remove gear (8) from the

crankshaft.
Illustration 336
g01209641
2. Install shaft assembly (6). Install bolts (5).
i02421100
Gear Group (Rear) - Install

SMCS Code: 1206-012; 1212-012
Table 72
Required Tools
Tool
Part Number
1P-0520
Part Description
Driver Gp
Qty
1
Illustration 337
g01209639
3. Use Tooling (A) to install bearing (4).
Illustration 335
g01209643
1. Install gear (8) onto the crankshaft. Install bolts (7).
Illustration 338
g01209637
4. Install gear (3). Install plate (2). Install bolts (1).

End By:
a. Install the flywheel housing. Refer to Disassembly
and Assembly, Flywheel Housing - Install.
102
KENR6052-01
i02647944
Piston Cooling Jets - Remove

and Install
4. Repeat Steps 2 and 3 for the remaining piston

cooling jets.
SMCS Code: 1331
Removal Procedure
1. Turn the battery disconnect switch to the OFF
position.
Illustration 341
g01206108
1. Install piston cooling jet (4). Install bolts (3).
Illustration 339
g01459651
NOTICE
component life.
2. Remove bolts (1). Remove side cover (2).
Illustration 342
g01459651
2. Install side cover (2). Install bolts (1).

3. Repeat Steps 1 and 2 for the remaining piston
cooling jets.
4. Turn the battery disconnect switch to the ON
position.
Illustration 340
g01206108
3. Remove bolts (3). Remove piston cooling jet (4).
KENR6052-01
103
i02717761
Bearing Clearance - Check
Ensure that the backs of the bearings and the
SMCS Code: 1203-535; 1219-535
bores are clean and dry.
Measurement Procedure
Ensure that the bearing locking tabs are properly

seated in the tab grooves.
Table 73
The crankshaft must be free of oil at the contact
Required Tools
Tool
Part
Number
198-9142
points of Tooling (A).
Qty
1. Put a piece of Tooling (A) on the crown of the

bearing that is in the cap.
Plastic Gauge (Green)

0.025 to 0.076 mm
(0.001 to 0.003 inch)
Plastic Gauge (Red)

0.051 to 0.152 mm
(0.002 to 0.006 inch)
198-9144
Plastic Gauge (Blue)

0.102 to 0.229 mm
(0.004 to 0.009 inch)
2. Use the correct torque-turn specifications in order

to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
198-9145
Plastic Gauge (Yellow)

0.230 to 0.510 mm
(0.009 to 0.020 inch)
Note: Do not turn the crankshaft when Tooling (A)

is installed.
198-9143
A
Part Description
The technician must be very careful to use Tooling (A)

correctly. The following points must be remembered:
Note: Plastic gauge may not be necessary when the

engine is in the chassis.
Note: Do not allow Tooling (A) to extend over the

edge of the bearing.
3. Carefully remove the cap, but do not remove

Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 343.
NOTICE
component life.
Note: Caterpillar does not recommend the checking
of the actual bearing clearances particularly on
small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.
Note: The measurements should be within
specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
Illustration 343
g01152855
Typical Example
4. Remove all of Tooling (A) before you install the

bearing cap.
104
KENR6052-01
Note: When Tooling (A) is used, the readings can

sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, Connecting Rod Bearing Journal and
Specifications Manual, Main Bearing Journal for the
correct clearances.
i02648007
Connecting Rod Bearings Remove and Install

SMCS Code: 1219-010
Removal Procedure
Table 74
Required Tools
Tool
Part Number
Qty
279-3473
Engine Turning
Tool
329-3831(1)
Air Power
Turning Tool
(1)
Illustration 345
Part
Description
g01431477
Note: Inspect the connecting rod and connecting rod

cap for the proper identification mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting rod
and the connecting rod cap, if necessary.
Optional
3. Remove bolts (3). Remove connecting rod caps

(4).
4. Push the connecting rod away from the crankshaft
and remove the upper half of the connecting rod
bearing.
Illustration 344
g01459651
1. Remove bolts (1). Remove side cover (2).

2. Use Tooling (A) to turn the flywheel in order
to access the connecting rod cap that will be
removed.
Illustration 346
g01431479
Note: Notice the location of the tabs when the

bearings are removed from the ODD and EVEN
connecting rod caps.
KENR6052-01
105
5. Position the connecting rod on the crankshaft.
5. Remove lower half (5) of the connecting rod

bearing from connecting rod cap (4).
Table 75
Required Tools
Tool
Part
Number
Part Description
4C-5593
Thread Lubricant
Qty
1
NOTICE
component life.
1. Check the clearance of the bearings. Refer to
Disassembly and Assembly, Bearing Clearance Check for the correct procedure.
2. Place clean engine oil on the connecting rod
bearings.
Illustration 348
g01431477
6. Position connecting rod cap (4) onto the

connecting rod. Ensure that the number on the
side of connecting rod cap (4) corresponds to the
number that is on the connecting rod.
7. Apply Tooling (B) under the heads of bolts (3) and
to the threads of bolts (3). Install bolts (3) finger
tight.
Illustration 349
g01431693
8. Use the following procedure to tighten bolts (3):

a. Tighten bolts (1) and (2) to a torque of
105 5 Nm (77 4 lb ft).
Illustration 347
g01431479
Note: Notice the location of the tabs on the ODD

and EVEN connecting rod caps before installing the
bearings.
3. Install lower half (5) of the connecting rod bearing
in connecting rod cap (4). Ensure that the tab
on the back of the bearing is in the bearing tab
groove on connecting rod cap (4).
4. Install the upper half of the connecting rod bearing
in the connecting rod. Ensure that the tab on the
back of the bearing is in the bearing tab groove
on the connecting rod.
b. Tighten bolts (3) and (4) to a torque of

105 5 Nm (77 4 lb ft).
c. Tighten bolts (5) and (6) to a torque of
105 5 Nm (77 4 lb ft).
d. Repeat Steps 8.a through 8.c.
e. Turn bolts (3) and (4) for an additional 90 5
degrees.
f. Turn bolts (5) and (6) for an additional 90 5
degrees.
106
KENR6052-01
g. Turn bolts (1) and (2) for an additional 90 5

degrees.
i03712702
Crankshaft Main Bearings Remove

SMCS Code: 1203-011
Removal Procedure
Table 76
Required Tools
Illustration 350
Tool
Part Number
253-3272
Cylinder
178-9312
Hose As
253-3276
Distribution
Coupler
227-6724
Electric Hydraulic
Pump Gp (120 V)
227-8834
Electric Hydraulic
Pump Gp (240 V)
191-5347
Hydraulic Pump Gp
156-7167
Manual Hydraulic
Pump
279-3473
Engine Turning
Tool
329-3831(2)
Air Power Turning

Tool
Bearing Driver
Guide Stud M20 2.5 by 250 MM
D(1)(3)
g01459651
9. Position side cover (2). Install bolts (1).
Ft-3134
Part Description
Qty
(1)
Use any of the pumps that are listed in Tooling (D) for this
procedure.
(3) The latest pumps and hoses require (22000 psi) capacity.
(2) Optional
Start By:
a. Remove the starting motors. Refer to Disassembly
and Assembly, Electric Starting Motor - Remove
or Disassembly and Assembly, Air Starting Motor
- Remove.
b. Remove the fuel filter base. Refer to Disassembly
and Assembly, Fuel Filter Base - Remove.
c. Remove the fuel pump. Refer to Disassembly and
Assembly, Fuel Pump - Remove.
d. Remove the engine oil pump. Refer to
- Remove.
e. Remove the engine oil cooler. Refer to
- Remove.
KENR6052-01
107
f. Remove the engine oil scavenge pump. Refer

Scavenge Pump - Remove.
Illustration 351
3. Install Tooling (A) onto the studs for the crankshaft

main bearing cap. Tighten the threaded collar of
Tooling (A). Loosen the threaded collar of Tooling
(A) by 1 1/2 turns. Attach Tooling (B) onto Tooling
(A). Attach Tooling (B) onto Tooling (C). Attach
Tooling (C) onto Tooling (D). Apply approximately
135 MPa (19580 psi) of pressure to Tooling (A).
Use the drive on Tooling (A) in order to loosen the
nuts for the crankshaft main bearings. Turn the
drive on Tooling (A) by approximately three turns.
Release the pressure on Tooling (A). Remove
Tooling (A).
g01212026
Illustration 354
g01212274
4. Remove crankshaft main bearing nuts (3).

Remove plate (4).
Illustration 352
g01212278
1. Remove bolts (1) and remove side cover (2).

Repeat for the remaining side covers on both
sides of the engine.
2. Remove bolt (5) from each side of the engine and
install Tooling (G).
Illustration 355
g01212288
5. Slide down crankshaft main bearing cap (6) on the

studs. Remove crankshaft main bearing (7) from
crankshaft main bearing cap (6).
6. Install Tooling (F) in order to remove the upper
crankshaft main bearing. If necessary, use Tooling
(E) in order to rotate the crankshaft and remove
the upper crankshaft main bearing.
Illustration 353
g01212105
108
KENR6052-01
i03722780
Crankshaft Main Bearings Install

SMCS Code: 1203-012
Table 77
Required Tools
Tool
Part Number
253-3272
Cylinder
178-9312
Hose As
253-3276
Distribution
Coupler
227-6724
Electric Hydraulic
Pump Gp (120 V)
227-8834
Electric Hydraulic
Pump Gp (240 V)
191-5347
Hydraulic Pump Gp
156-7167
Manual Hydraulic
Pump
279-3473
Engine Turning
Tool
329-3831(2)
Air Power Turning

Tool
Bearing Driver
D(1)(3)
Part Description
Qty
FT-3134
Guide Stud
M20-2.5 by 250
MM
284-5266
Spanner Wrench
(1)
procedure.
(3) The latest pumps and hoses require (22000 psi)capacity.
(2) Optional
Illustration 356
g01212288
3. Lightly lubricate crankshaft main bearing (7) with

clean engine oil. Install crankshaft main bearing
(7) into crankshaft main bearing cap (6). Lift
crankshaft main bearing cap (6) into position.
Illustration 357
g01212278
4. Lubricate bolts (5) with clean engine oil. Remove

Tooling (G). Install bolts (5) finger tight.
1. Lubricate main bearing studs (8) with clean engine

oil. Use Tooling (H) and a suitable torque wrench
in order to check the torque on main bearing studs
(8). Tighten main bearing studs (8) to a torque of
100 20 Nm (74 15 lb ft).
Note: Be sure that the back of the main bearing is
clean and free from oil.
2. Lightly lubricate the upper crankshaft main bearing
with clean engine oil. If necessary, use Tooling (E)
in order to rotate the crankshaft and remove main
bearing. Use Tooling (F) and install the upper
crankshaft main bearing into the cylinder block.
Illustration 358
g01212274
5. Lubricate the main bearing studs with clean

engine oil. Install plate (4). Install nuts (3) for the
crankshaft main bearings finger tight.
KENR6052-01
Illustration 359
109
g01212278
6. Start at the front of the engine and tighten bolts (5)

on the right side of the cylinder block to a torque
of 100 20 Nm (74 15 lb ft).
Illustration 360
g01212105
Note: Show 14 to 15 threads or 28 to 30 millimeters

of protrusion of the stud above the nut before tension
is applied. Show 16 to 17 threads or 32 to 34
millimeters of protrusion of the stud above the nut
after tension is applied.
7. Install Tooling (A) onto the studs for the crankshaft
main bearing cap. Tighten the threaded collar
of Tooling (A). Attach Tooling (B) onto Tooling
(A). Attach Tooling (C) onto Tooling (D). Apply
approximately 135 MPa (19580 psi) of pressure to
Tooling (B). Use the drive on Tooling (A) in order to
tighten the nuts for the crankshaft main bearings.
Release the pressure on Tooling (A). Reapply
approximately 135 MPa (19580 psi) of pressure
to Tooling (A). Recheck nuts (3) for tightness.
Remove Tooling (A).
Illustration 361
g01212278
8. Start at the front of the engine and tighten bolts

(5) on the left side of the cylinder block to a torque
of 100 20 Nm (74 15 lb ft).
Illustration 362
g01212278
9. Start at the front of the engine and tighten bolts (5)

on the right side of the cylinder block to a torque
of 530 70 Nm (391 52 lb ft).
of 530 70 Nm (391 52 lb ft).
Illustration 363
g01212026
110
KENR6052-01
11. Install side cover (2). Install bolts (1). Repeat for
the remaining side covers on both sides of the
engine.
End By:
a. Install the engine oil scavenge pump. Refer
Scavenge Pump - Install.
b. Install the engine oil cooler. Refer to Disassembly
c. Install the engine oil pump. Refer to Disassembly
d. Install the fuel pump. Refer to Disassembly and
Assembly, Fuel Pump - Install.
e. Install the fuel filter base. Refer to Disassembly
and Assembly, Fuel Filter Base - Install.
NOTICE
products.
mandates.
1. Drain the engine oil into a suitable container for
storage or for disposal. Refer to Operation and
f. Install the starting motors. Refer to Disassembly

and Assembly, Electric Starting Motor - Install or
Disassembly and Assembly, Air Starting Motor Install.
i03714141
Pistons, Liners, and

Connecting Rods - Remove
SMCS Code: 1216-011; 1225-011
Removal Procedure
Table 78
Required Tools
Tool
Part Number
(1)
Part Description
Qty
279-3473
Engine Turning Tool
329-3831(1)
Air Power Turning Tool
274-5875
Guide
276-0010
Bolt
8T-2686
Puller Group
328-5926
Spacer
322-3564
Cylinder Puller
Optional
Start By:
b. Remove the piston cooling jet. Refer to
Disassembly and Assembly, Piston Cooling Jet
Illustration 364
g01831951
Note: Inspect the connecting rod and connecting rod

cap for the proper identification mark. The connecting
rod and the connecting rod cap should have an
etched number on the side. The number should
match the cylinder number. Mark the connecting rod
and the connecting rod cap, if necessary. Careful
handling is required for fractured connecting rods.
The connecting rod and the rod cap should be placed
on the sides in order to prevent damage. When
possible, the connecting rod and the rod cap should
be bolted together in order to prevent damage.
2. Use Tooling (A) to rotate the flywheel in order
removed.
KENR6052-01
111
3. Remove bolts (1) and connecting rod cap (2).

Position the crankshaft so that the piston is at the
bottom dead center. Inspect the connecting rod
bearing for wear or for damage.
Illustration 365
g01240845
4. Install Tooling (B) onto the connecting rod.
Illustration 367
g01997933
7. Install Tooling (D). Remove Tooling (C).

Note: Do not remove the cylinder pack with Tooling
(C).
Illustration 366
g01240763
5. Install Tooling (C). Hold the bolt of Tooling (C) and

turn the nut. Turn the nut until the nut is tight.
6. Rotate the engine in order to position the cylinder
pack to the proper height and install Tooling (D).
Illustration 368
g01765495
8. Install Tooling (E) onto the piston liner. Rotate

the engine in order to position the piston to the
top. Attach Tooling (E) to the piston. Attach a
suitable lifting device onto Tooling (E). The weight
of the piston, the liner, and the connecting rod is
approximately 50 kg (110 lb). Remove Tooling (D).
112
KENR6052-01
g01765496
Illustration 369
9. Remove cylinder pack (3) from the cylinder block.

i02998187
Pistons and Connecting Rods

- Disassemble
Illustration 370
g01520323

connecting rod (1). The weight of connecting rod
(1) and the piston is approximately 23 kg (50 lb).
Remove connecting rod (1) and the piston from
liner (2).
SMCS Code: 1225-015
Table 79
Required Tools
Tool
Part
Number
138-7575
Link Bracket
1P-1861
Retaining Ring
Pliers
271-0504
Ring Expander
Part Description
Qty
Start By:
a. Remove the pistons, liners, and connecting rods.
Refer to Disassembly and Assembly, Pistons,
Liners, and Connecting Rods - Remove.
Illustration 371
2. Remove O-ring seals (3) from liner (2).
g01229379
KENR6052-01
113
i03091751
Pistons and Connecting Rods

- Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 80
Required Tools
Illustration 372
g01229403
3. Use Tooling (B) in order to remove retaining ring

(4). Remove wrist pin (5) and remove connecting
rod (1) from piston (6).
Tool
Part Number
138-7575
Link Bracket
1P-1861
Retaining Ring
Pliers
271-0504
Ring Expander
255-8897
Ring Compressor
327-8644
Ring Groove
Gage-Top
327-8645
Ring Groove
Gage-Second
327-8646
Ring Groove
Gage-Oil
Illustration 373
Part Description
Qty
g01229404
4. Use Tooling (C) and remove piston rings (7) from

piston (6).
Illustration 374
g01229404
1. Use Tooling (E) for the ring grooves. Use Tooling

(C) and install piston rings (7) onto piston (6).
Install the top ring with the side that is marked
UP 1 toward the top of the piston. Install the
intermediate ring with the side that is marked UP
2 toward the top of the piston. The oil ring spring
ends must be assembled 180 degrees from the
ring end gap. After the rings have been installed,
rotate the rings so that the end gaps are located
120 degrees from each other. Oil ring end gap
must be in the pin bore plane.
114
KENR6052-01
4. Coat piston (6) and the piston rings with clean

engine oil. Install Tooling (D) onto piston (6).
Tighten Tooling (D) in order to compress the piston
rings.
Illustration 375
g01229403
2. Coat connecting rod (1) and wrist pin (5) with

clean engine oil. Install connecting rod (1) into
piston (6). Install wrist pin (5) into piston (6) and
connecting rod (1). Use Tooling (B) in order to
install retaining ring (4). Position retaining ring (4)
with the opening toward the bottom of the piston.
Illustration 376
Illustration 378
g01240872
5. Coat the inside of liner (2) with clean engine oil.

Attach Tooling (A) and a suitable lifting device onto
the connecting rod. The weight of the connecting
rod and the piston assembly is approximately
23 kg (50 lb). Install the connecting rod and the
piston assembly into the bottom side of liner (2).
g01229379
3. Install O-ring seals (3) onto liner (2).

Illustration 379
g01520432
6. Remove Tooling (D) from liner (2).

Note: Do not permit the piston to go past the top
dead center position. If the piston goes past the top
dead center position, the piston rings will lock into the
cuff ring bore.
End By:
Illustration 377
g01240871
a. Install the pistons, liners, and connecting rods.

Refer to Disassembly and Assembly, Pistons,
Liners, and Connecting Rods - Install.
KENR6052-01
115
i03710841
Pistons, Liners, and

Connecting Rods - Install
SMCS Code: 1216-012; 1225-012
Table 81
Required Tools
Tool
B
E
F
G
(1)
Part
Number
Part Description
279-3473
Engine Turning Tool
329-3831(1)
Air Power Turning

Tool
274-5875
Guide
276-0010
Bolt
322-3564
Puller Group
288-9169
Installation Bracket
Liner Installer
Thread Lubricant
2P8260
4C-5593
Qty
2. Attach a suitable lifting device onto Tooling

(E). The weight of the piston, the liner, and the
connecting rod is approximately 50 kg (110 lb).
Install Tooling (B) onto the connecting rod. Coat
the liner bore of the cylinder block and the O-ring
seals on the outside of the cylinder liner with liquid
soap. Install cylinder pack (3) into the cylinder
block.
Note: Inspect the connecting rod bearing for wear
or for damage. If necessary, replace the connecting
rod bearing. Refer to Disassembly and Assembly,
Connecting Rod Bearings - Remove and Install for
the proper procedure. Position the connecting rod so
that the chamfer is toward the crankshaft. Install the
piston, the liner, and the connecting rod as a unit.
Optional
Note: Ensure that the top O-ring seal for the liner is at
least 20 C (68 F) before installation of liners into the
cylinder block. Assembly with a cold seal may result
in damage to the O-ring seal or to the installation tool.
Illustration 381
3. Remove Tooling (E).
Illustration 382
Illustration 380
g01765496
1. Rotate the engine in order to position the

crankshaft at the bottom.
g01765495
g01945551
4. Install Tooling (F). Use Tooling (F) in order to seat

the liner into the cylinder block. Position the cuff
ring bore to 5 1 mm (0.1969 0.0394 inch)
above the top of the cylinder liner in order to hold
on the fire ring.
116
KENR6052-01

105 5 Nm (77 4 lb ft).
105 5 Nm (77 4 lb ft).
105 5 Nm (77 4 lb ft).
degrees.
Illustration 383
g01240845
5. Remove Tooling (B) from the connecting rod.

degrees.
degrees.
End By:
a. Install the piston cooling jet. Refer to Disassembly
and Assembly, Piston Cooling Jet - Remove and
Install.
b. Install the cylinder head. Refer to Disassembly
i02648188
Camshaft - Remove
SMCS Code: 1210-011
Illustration 384
g01831951
Note: Match the tabs on the ODD and EVEN

connecting rod caps with the connecting rods.
6. Install connecting rod cap (2). Apply Tooling (G)
under the head bolts (1) and to the threads of
bolts (1). Install bolts (1).
7. Use Tooling (A) to rotate the flywheel in order
installed.
Removal Procedure
Table 82
Required Tools
Tool
Part Number
Part Description
282-9962
Guide
255-2820
Camshaft Pilot
8T-3169
Crank As
Qty
Start By:
a. Remove the camshaft followers. Refer to
Disassembly and Assembly, Camshaft Followers
- Remove.
Illustration 385
g01431693
KENR6052-01
117
NOTICE
products.
mandates.
1. Drain the coolant from the cooling system into a
suitable container for storage or disposal. Refer
Illustration 388

retainer (13).
Illustration 389
Illustration 386
g01837093
2. Disconnect harness assemblies (3). Remove bolts

(4). Remove cover (5). Remove bolts (2). Remove
lifting bracket (1).
g01228236
g01837094
6. Disconnect harness assembly (15). Disconnect

tube assembly (16).
7. Remove bolts (19). Remove elbow (18).
Illustration 390
Illustration 387
g01228235
4. Remove bolts (8). Remove bolt (9). Remove

spacer (10). Remove cam gear (11).
Typical Example
g01228274
118
KENR6052-01
i03092004
Camshaft Bearings - Remove

SMCS Code: 1211-011
Removal Procedure
Start By:
a. Remove the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove.
Manual Removal
Illustration 391
g01228276
Table 83
Typical Example
Required Tools
9. Apply a thin coat of oil to Tooling (A) and Tooling

(B). Install Tooling (A) and leave the bolts loose.
Install Tooling (B). Tighten the bolts for Tooling
(A). Install Tooling (C). Use Tooling (C) in order to
rotate the camshaft. Rotate the camshaft in order
to remove the camshaft.
Tool
Part Number
Bearing Pilot
125-2740
Back Up Plate
125-2741
Bearing Sleeve
6V-4013
Screw
6V-4010
Puller Plate
8M-8778
Taperlock Stud
2J-3506
Full Nut
5P-8248
Hard Washer
Illustration 393
g01329080
10. Remove camshaft (20) halfway from the engine.

Use a suitable lifting device in order to support
camshaft (20). The weight of camshaft (20)
is approximately 95 kg (210 lb). Remove the
remaining portion of camshaft (20).
Qty
125-2739
Note: The camshaft can be removed from either end

of the engine.
Illustration 392
Part Description
g01203149
205
1. Install the sleeve of Tooling (A) into camshaft

bearing (1). Install the remainder of Tooling (A).
KENR6052-01
119
g01203308
Illustration 394
2. Install Tooling (B). Remove camshaft bearing (1).
g01203225
Illustration 396
2. Install Tooling (B) and Tooling (C). Remove

camshaft bearing (1).
Hydraulic Removal
i03092039
Table 84
Camshaft Bearings - Install
Required Tools
Tool
Part Number
Part Description
Qty
125-2739
Bearing Pilot
125-2740
Back Up Plate
125-2741
Bearing Sleeve
6V-4013
Screw
6V-4010
Puller Plate
8M-8778
Taperlock Stud
2J-3506
Full Nut
5P-8248
Hard Washer
5P-5247
Hydraulic Puller
3S-6224
Electric Hydraulic
Pump Gp (115 V)
8S-8033
Electric Hydraulic
Pump Gp (230 V)
SMCS Code: 1211-012
Manual Procedure
Table 85
Required Tools
Tool
Part Number
Part Description
Qty
125-2739
Bearing Pilot
125-2740
Back Up Plate
125-2741
Bearing Sleeve
6V-4013
Screw
6V-4010
Puller Plate
8M-8778
Taperlock Stud
2J-3506
Full Nut
5P-8248
Hard Washer
NOTICE
component life.
Illustration 395
g01203149
1. Install the sleeve of Tooling (A) into camshaft

bearing (1). Install the remainder of Tooling (A).
120
KENR6052-01
Hydraulic Procedure
Table 86
Required Tools
Tool
Illustration 397
g01203522
Part Number
Part Description
Qty
125-2739
Bearing Pilot
125-2740
Back Up Plate
125-2741
Bearing Sleeve
6V-4013
Screw
6V-4010
Puller Plate
8M-8778
Taperlock Stud
2J-3506
Full Nut
5P-8248
Hard Washer
5P-5247
Hydraulic Puller
3S-6224
Electric Hydraulic
Pump Gp (115 V)
8S-8033
Electric Hydraulic
Pump Gp (230 V)
8S-8292
Extension
1. Install camshaft bearing (1) onto Tooling (A).
NOTICE
component life.
Illustration 398
g01203523
Illustration 399
g01204034
Note: The camshaft bearing joint must be in the 2

O'clock or the 10 O'clock position. The oil hole must
be located on the centerline of the bore.
2. Position Tooling (A) and camshaft bearing (1) into
the bearing bore. Make sure that the groove in the
back of camshaft bearing (1) is aligned with oil
hole (2) in the cylinder block. Install Tooling (B).
Install camshaft bearing (1).
Illustration 400
g01203522
1. Install camshaft bearing (1) onto Tooling (A).
KENR6052-01
121
i02648725
Camshaft - Install
SMCS Code: 1210-012
Table 87
Required Tools
Illustration 401
g01203527
Illustration 402
g01204034
Note: The camshaft bearing joint must be in the 2

O'clock or the 10 O'clock position. The oil hole must
be located on the centerline of the bore.
Tool
Part Number
282-9962
Guide
255-2820
Camshaft Pilot
8T-3169
Crank As
Illustration 403
Part Description
Qty
g01228274
Typical Example
2. Position Tooling (A) and camshaft bearing (1) into

the bearing bore. Make sure that the groove in the
back of camshaft bearing (1) is aligned with oil
hole (2) in the cylinder block. Install Tooling (B)
and Tooling (C). Install camshaft bearing (1).
End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, Camshaft - Install.
Illustration 404
g01228276
Typical Example
Note: The camshaft can be installed from either end

of the engine.
1. Apply a thin coat of oil to Tooling (A) and Tooling
(B). Install Tooling (B) into the ends of the
camshaft. Install Tooling (C).
Note: If Tooling (A) was removed use the following
Steps in order to install Tooling (A).
122
KENR6052-01
a. Install Tooling (B) into the engine until Tooling

(B) is through the second camshaft bearing.
b. Slide Tooling (A) over Tooling (B).
c. Tighten the bolts for Tooling (A).
d. Remove Tooling (B).
Illustration 407
g01228236
6. Install retainer (13). Install the washers and bolts

(12).
Illustration 405
g01329080
2. Attach a suitable lifting device to the middle of

camshaft (20). The weight of camshaft (20) is
approximately 95 kg (210 lb). Install camshaft
(20) halfway into the engine. Remove the suitable
lifting device. Install camshaft (20). Use Tooling
(C) in order to rotate camshaft (20). Rotate
camshaft (20) in order to install camshaft (20).
Illustration 406
Illustration 408
g01228235
7. Rotate the engine so that the number one piston

is at top dead center on the compression stroke.
Refer to Testing and Adjusting, Finding Top
Center Position for No. 1 Piston. Install cam gear
(11). Install spacer (10). Install bolt (9). Install bolts
(8).
g01837094
3. Install cover (17). Install bolts (14).

4. Install elbow (18). Install bolts (19).
5. Connect tube assembly (16). Connect harness
assembly (15).
Illustration 409
8. Install cover (7). Install bolts (6).
g01837093
KENR6052-01
123
9. Install lifting bracket (1). Install bolts (2). Install

cover (5). Install bolts (4). Connect harness
assemblies (3).
d. Remove the flywheel housing. Refer to

- Remove.

e. Remove the engine oil cooler. Refer to

- Remove.
End By:
1. Use Tooling (A) in order to rotate the engine to

approximately 120 degrees.
a. Install the camshaft followers. Refer to

Disassembly and Assembly, Camshaft Followers
- Install.
i03712924
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Table 88
Required Tools
Tool
Part Number
Part Description
Qty
4C-9832
Engine Rollover Stand
284-8777
Adapter Plate (Rear)
284-8766
Adapter Plate (Front)
253-3272
Cylinder
Illustration 410
178-9312
Hose As
253-3276
Distribution Coupler
227-6724
Electric Hydraulic
Pump Gp (120 V)
227-8834
Electric Hydraulic
Pump Gp (240 V)
191-5347
Hydraulic Pump Gp
156-7167
Manual Hydraulic
Pump
284-5266
Spanner Wrench
2. Install Tooling (B) onto the studs for the crankshaft

main bearing cap. Tighten threaded collar (1) of
Tooling (B). Loosen threaded collar (1) of Tooling
(B) by 1 1/2 turns. Attach Tooling (C) onto Tooling
(B). Attach Tooling (C) onto Tooling (D). Attach
Tooling (D) onto Tooling (E). Apply approximately
135 MPa (19580 psi) of pressure to Tooling (B).
Use drive (2) on Tooling (B) in order to loosen the
nuts for the crankshaft main bearings. Turn drive
(2) on Tooling (B) by approximately three turns.
Release the pressure on Tooling (B). Remove
Tooling (B). Repeat for the remaining main bearing
caps.
E(1)(2)
F
(1)
procedure.
Start By:
a. Remove rocker arm shaft assemblies. Refer to
Disassembly and Assembly, Rocker Shaft ans
Push Rods - Remove.
b. Remove the engine oil pan. Refer to Disassembly
c. Remove the front housing. Refer to Disassembly
and Assembly, Front Drive Housing - Remove
and Install.
g01224384
124
Illustration 411
KENR6052-01
g01432170
3. Remove nuts (3) for the crankshaft main bearings.

Remove plate (4). Remove bolts (5) from each
side of the engine.
Illustration 413
g01432172
6. Number counterweights (13) for assembly

purposes. Remove bolts (11). Remove
counterweights (13). The weight of counterweights
(13) is approximately 18 kg (40 lb). Number the
rod caps and the connecting rods for assembly
purposes. Remove bolts (8). Remove rod caps
(9). Lay rod caps (9) on the side in order to
prevent damage. Position pistons (10) away from
crankshaft (12).
connecting rod caps with the connecting rod.
Illustration 412
g01432171
4. Remove main bearing cap (6) and lower main

bearing (7).
5. Use Tooling (A) in order to rotate the engine to
approximately 180 degrees so that the crankshaft
is on top.
Illustration 414
g01224401
Note: If the counterweights are installed on

the crankshaft, the weight of the crankshaft is
7. Attach a suitable lifting device onto crankshaft (12).
The weight of crankshaft (12) is approximately
748 kg (1650 lb). Remove crankshaft (12).
KENR6052-01
125
i03712941
Crankshaft - Install
SMCS Code: 1202-012
Table 89
Required Tools
Tool
Illustration 415
Part Number
Part Description
Qty
4C-9832
Engine Rollover Stand
284-8777
Adapter Plate (Rear)
284-8766
Adapter Plate (Front)
253-3272
Cylinder
178-9312
Hose As
253-3276
Distribution Coupler
227-6724
Electric Hydraulic
Pump Gp (120 V)
227-8834
Electric Hydraulic
Pump Gp (240 V)
191-5347
Hydraulic Pump Gp
156-7167
Manual Hydraulic
Pump
284-5266
Spanner Wrench
g01224408
8. Remove upper main bearings (16) from cylinder

block (14). Remove thrust bearing (15) from
cylinder block (14).
E(1)(2)
F
(1)
procedure.
Illustration 416
g01224414
9. Install Tooling (F) onto main bearing stud (17).

Use a suitable ratchet and Tooling (F) in order to
remove main bearing stud (17).
Illustration 417
g01224414
1. Lubricate main bearing studs (17) with clean

engine oil. Install main bearing stud (17). Use
Tooling (F) and a suitable torque wrench in order
to tighten main bearing stud (17). Tighten main
bearing stud (17) to a torque of 100 20 Nm
(74 15 lb ft).
126
Illustration 418
KENR6052-01
g01224408
2. Install thrust bearing (15) into the rear of cylinder

block (14). Lightly lubricate upper main bearings
(16) and the upper connecting rod bearings with
clean engine oil. Install upper main bearings (16)
into cylinder block (14).
Illustration 420
g01432463

connecting rod caps with the connecting rod.
5. Position pistons (10) toward crankshaft (12).
Lubricate the bearings for rod caps (9) with clean
engine oil. Install rod caps (9). Apply Tooling (E)
under the bolt heads (8) and to the bolt threads
(3). Install bolts (8) finger tight.
Illustration 419
g01224401
3. Attach a suitable lifting device onto crankshaft (12).

The weight of crankshaft (12) is approximately
748 kg (1650 lb). Install crankshaft (12).
4. Use Tooling (A) to rotate the engine slightly above
the horizontal position.
Illustration 421
g01431693

105 5 Nm (77 4 lb ft).
105 5 Nm (77 4 lb ft).
105 5 Nm (77 4 lb ft).
degrees.
degrees.
degrees.
KENR6052-01
Illustration 422
127
g01432454
7. Install counterweights (13). The weight of

counterweights (13) is approximately 18 kg (40 lb).
Lubricate the threads, the shank, the washer, and
the seat of bolts (11) with Tooling (E). Install bolts
(11). Tighten bolts (11) to a torque of 220 20 Nm
(162 15 lb ft). Turn bolts (11) and additional 90
5 degrees.
Illustration 423
Illustration 424
g01432170
9. Lubricate the main bearing studs with clean

engine oil. Install plate (4). Install nuts (3) for the
crankshaft main bearings finger tight. Lubricate
bolts (5) with clean engine oil. Install bolts (5)
finger tight.
(5) on the right side of the cylinder block to a
g01432171
8. Lubricate lower main bearing (7) with clean engine

oil. Install lower main bearing (7) into main bearing
cap (6). Install main bearing cap (6).
Illustration 425
g01224384
128
KENR6052-01
11. Install Tooling (B) onto the studs for the crankshaft
main bearing cap. Tighten threaded collar (1)
of Tooling (B). Attach Tooling (C) onto Tooling
(B). Attach Tooling (C) onto Tooling (D). Attach
Tooling (D) onto Tooling (E). Apply approximately
Use drive (2) on Tooling (B) in order to tighten the
nuts for the crankshaft main bearings. Release the
pressure on Tooling (B). Reapply approximately
Recheck nuts (2) for tightness. Remove Tooling
(B).
i02650060
Air Compressor - Remove and

Install
SMCS Code: 1803-010
Removal Procedure
Table 90
Required Tools
Tool
A
Part
Number
138-7573
Part Description
Link Bracket
Qty
1
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
NOTICE
Illustration 426
g01225172

of 100 20 Nm (74 15 lb ft).
(5) on the right side of the cylinder block to a
of 530 70 Nm (391 52 lb ft).
End By:
a. Install the engine oil cooler. Refer to Disassembly
b. Install the flywheel housing. Refer to Disassembly
c. Install the front housing. Refer to Disassembly
and Assembly, Front Drive Housing - Remove
and Install.
d. Install the engine oil pan. Refer to Disassembly
e. Install rocker arm shaft assemblies. Refer to
Disassembly and Assembly, Rocker Shaft ans

component life.
NOTICE
products.
mandates.
1. Remove the air pressure from the air tank and
drain the coolant from the cooling system.
KENR6052-01
129
g01857216
Illustration 427
2. Disconnect hose assemblies (2), (3), (4), (6), and

(7) from air compressor (1).
3. Install Tooling (A) and a suitable lifting device to
air compressor (1). The weight of air compressor
5. Remove air compressor (1) and the gasket.
5. Fill the cooling system with coolant to the

correct level. Refer to the Operation and
Maintenance Manual, Refill Capacities and
Recommendations.
Table 91
Required Tools
Part Description
2. Position air compressor (1) in the front housing

cover.
4. Connect hose assemblies (2), (3), (4), (6), and (7)

into air compressor (1).
Part
Number
1. Install Tooling (A) and a suitable lifting device to

air compressor (1). The weight of air compressor
3. Apply Tooling (B) to the threads of bolts (5). Install

the washers and bolts (5).
4. Remove bolts (5) and the washers.
Tool
g01857216
Illustration 428
Qty
138-7573
Link Bracket
i02648908
9S-3263
Thread Lock Compound
Engine Trunnion - Remove and

Install
NOTICE
component life.
SMCS Code: 1153-010
Removal Procedure
Table 92
Required Tools
Tool
Part
Number
8T-0514
Part Description
Adjusting Screw
Qty
2
130
KENR6052-01
Start By:
a. Remove the vibration damper. Refer to
and Pulley - Remove and Install.
Illustration 431
g01844513
Illustration 432
g01844455
g01844455
Illustration 429
1. Insert Tooling (A) into the front housing.

g01844513
Illustration 430
1. Remove two bolts (2) and the washers from

engine trunnion (1). Install Tooling (A).
2. Attach a suitable lifting device to engine
trunnion (1). The weight of engine trunnion (1) is
3. Remove remaining bolts (2). Slide engine trunnion
(1) forward on Tooling (A).
4. Remove engine trunnion (1).
Table 93
Required Tools
Tool
Part
Number
8T-0514
Part Description
Adjusting Screw
Qty
2
2. Attach a suitable lifting device to engine

trunnion (1). The weight of engine trunnion (1) is
3. Position engine trunnion (1) on Tooling (A).
Remove the suitable lifting device and slide engine
trunnion (1) on Tooling (A) into position. Install the
washers and bolts (2). Remove Tooling (A) and
install two bolts (2).
End By:
and Assembly, Vibration Damper and Pulley Remove and Install.
KENR6052-01
131
i02649318
Accessory Drive (Rear) Remove

SMCS Code: 1207-011-RE
Removal Procedure
Table 94
Required Tools
Tool
Part Number
Part Description
Qty
1P-0520
Driver
1P-0510
Driver
Start By:
a. Remove the flywheel housing. Refer to
- Remove.
Illustration 434
g01329883
3. Remove gear (7) from flywheel housing (1).

4. Use Tooling (A) to remove the bearing from gear
(7).
Illustration 433
g01329881
1. Remove bolt (3), plate (2), and yoke (4) from the
shaft.
2. Remove bolts (6), idler shaft (5), and the O-ring
seal from flywheel housing (1).
Illustration 435
g01329885
5. Remove nuts (10) and the washers.

6. Remove adapter (8), O-ring seal (9), and thrust
washer (11) from the shaft.
7. Remove the lip seal and the dirt seal. Use Tooling
(B) and a suitable press to remove the bearings.
132
Illustration 436
KENR6052-01
g01329886
8. Remove bolts (13) and the washers.

9. Remove shaft (12) and gear (14) from flywheel
housing (1).
g01329890
Illustration 438
11. Remove cage assembly (16) from the front of

flywheel housing (1). If necessary, remove studs
(17).
12. Use Tooling (B) and a suitable press to remove
the bearing from cage assembly (16).
i03583042
Accessory Drive (Rear) - Install

SMCS Code: 1207-012-RE
Table 95
Required Tools
Illustration 437
g01329888
10. Remove bolts (15), the washers, and the sealing

washers from the back of flywheel housing (1).
Tool
Part Number
Part Description
Qty
1P-0520
Driver
1P-0510
Driver
1. Check all of the O-ring seals and the components

of the rear accessory drive for wear or damage.
Replace the components of the rear accessory
drive if it is necessary.
2. Lubricate the O-ring seals with clean engine oil
prior to installation.
3. Verify that all the components of the rear
accessory drive are clean and free of foreign
material prior to installation.
KENR6052-01
133
8. Install bolts (15), the washers, and the sealing

washers through the back of flywheel housing (1)
in order to secure the cage assembly in flywheel
housing (1). Tighten bolts (15) to a torque of
100 20 Nm (74 15 lb ft).
Illustration 439
g01329890
4. If necessary, install studs (17).

5. Use Tooling (B) to Install the bearing into cage
assembly (16).
Illustration 441
6. Position cage assembly (16) in flywheel housing

(1).
9. Position gear (14) inside flywheel housing (1) for

installation.
7. Install the thrust washer over the dowels on cage

assembly (16).
10. Install shaft (12). Install bolts (13) and the

washers. Tighten bolts (13) to a torque of
300 40 Nm (221 30 lb ft).
Note: Install the thrust washer so that the smaller

dowel hole in the thrust washer is on the upper dowel
of the cage assembly (16). Lightly tap the washer
onto the dowel so that the washer is flush with the
cage assembly (16).
Illustration 442
g01329886
g01329885
Note: A new lip seal must be installed. Use the

plastic sleeve to prevent the inversion of the lip seal.
Illustration 440
g01329888
11. Use Tooling (B) to install the bearing into adapter

(8). Install the new lip seal into adapter (8).
134
KENR6052-01
12. Install thrust washer (11).

13. Install O-ring seal (9) on adapter (8) and install
adapter (8) on the shaft.
14. Install the washers and nuts (10). Tighten nuts
(10) to a torque of 63 10 Nm (47 7 lb ft).
15. Install the dirt seal into adapter (8).
Illustration 443
20. Install yoke (4) to the shaft with plate (2) and bolt
(3). Tighten bolt (3) to a torque of 900 100 Nm
(664 74 lb ft).
End By:
a. Install the flywheel housing. Refer to Disassembly
g01329883
16. Use Tooling (A) to install the bearing into gear (7).
17. Position gear (7) into flywheel housing (1).
Illustration 444
19. Install bolts (6). Tighten bolts (6) to a torque of

100 20 Nm (74 15 lb ft).
g01329881
18. Install the O-ring seal on idler shaft (5). Install

idler shaft (5) into the gear in flywheel housing (1).
KENR6052-01
135
Index Section
Index
A
Accessory Drive (Rear) - Install........................... 132
Installation Procedure ...................................... 132
Accessory Drive (Rear) - Remove....................... 131
Removal Procedure ......................................... 131
Air Compressor - Remove and Install.................. 128
Air Inlet Manifold - Remove and Install.................. 23
Installation Procedure ........................................ 23
Removal Procedure ........................................... 23
Air Starting Motor - Install ........................................ 4
Installation Procedure .......................................... 4
Air Starting Motor - Remove .................................... 4
Removal Procedure ............................................. 4
Auxiliary Water Pump - Assemble ......................... 37
Assembly Procedure.......................................... 37
Auxiliary Water Pump - Disassemble .................... 35
Disassembly Procedure ..................................... 35
Auxiliary Water Pump - Install ............................... 40
Auxiliary Water Pump - Remove ........................... 35
B
Bearing Clearance - Check ................................. 103
Measurement Procedure ................................. 103
C
Camshaft - Install................................................. 121
Camshaft - Remove.............................................. 116
Removal Procedure .......................................... 116
Camshaft Bearings - Install .................................. 119
Installation Procedure ....................................... 119
Camshaft Bearings - Remove .............................. 118
Connecting Rod Bearings - Remove and Install.. 104
Crankcase Breather - Remove and Install............. 66
Crankshaft - Install............................................... 125
Crankshaft - Remove........................................... 123
Crankshaft Front Seal - Install ............................... 91
Crankshaft Front Seal - Remove ........................... 91
Crankshaft Main Bearings - Install....................... 108
Crankshaft Main Bearings - Remove................... 106
Crankshaft Rear Seal - Install................................

Installation Procedure ........................................
Crankshaft Rear Seal - Remove............................
Removal Procedure ...........................................
Cylinder Head - Install ...........................................
Cylinder Head - Remove .......................................
94
94
93
93
78
78
77
77
D
Disassembly and Assembly Section........................ 4
E
Electronic Control Module (Engine) - Remove and
Install ..................................................................... 5
Electronic Unit Injector - Install .............................. 74
Electronic Unit Injector - Remove .......................... 72
Electronic Unit Injector Sleeve - Install .................. 76
Electronic Unit Injector Sleeve - Remove .............. 75
Engine Oil and Water Pump Drive - Assemble...... 53
Engine Oil and Water Pump Drive - Disassemble.. 53
Engine Oil and Water Pump Drive - Install ............ 54
Engine Oil and Water Pump Drive - Remove ........ 52
Engine Oil Cooler - Assemble ............................... 43
Engine Oil Cooler - Disassemble........................... 42
Engine Oil Cooler - Install...................................... 43
Engine Oil Cooler - Remove.................................. 41
Engine Oil Filter Housing - Install .......................... 52
Engine Oil Filter Housing - Remove ...................... 51
Engine Oil Pan - Assemble.................................... 59
Engine Oil Pan - Disassemble............................... 58
Engine Oil Pan - Install .......................................... 59
Engine Oil Pan - Remove ...................................... 57
Engine Oil Pump - Assemble................................. 48
136
Index Section
Engine Oil Pump - Disassemble............................ 47

Engine Oil Pump - Install ....................................... 49
Engine Oil Pump - Remove ................................... 44
Engine Oil Scavenge Pump - Assemble................ 63
Engine Oil Scavenge Pump - Disassemble........... 62
Engine Oil Scavenge Pump - Install ...................... 65
Engine Oil Scavenge Pump - Remove .................. 61
Engine Oil Screen - Remove and Install................ 55
Engine Trunnion - Remove and Install ................ 129
Exhaust Elbow - Remove and Install..................... 23
Exhaust Manifold - Remove and Install ................. 24
F
Flow Limiter - Remove and Install ......................... 15
Flywheel - Remove and Install .............................. 92
Flywheel Housing - Install...................................... 96
Flywheel Housing - Remove.................................. 95
Front Drive Housing - Remove and Install............. 87
Fuel and Auxiliary Water Pump Drive - Remove and
Install ................................................................... 32
Fuel Control Valve - Remove and Install ............... 17
Fuel Filter Housing - Install.................................. 78
Fuel Filter Housing - Remove (Secondary) ......... 67
Fuel Priming Pump - Remove and Install ................ 9
Fuel Pump (High Pressure) - Remove and Install.. 18
Fuel Transfer Pump - Install .................................. 10
KENR6052-01
Fuel Transfer Pump - Remove .............................. 10

G
Gear Group (Rear) - Install..................................
Installation Procedure ......................................
Gear Group (Rear) - Remove..............................
Removal Procedure .........................................
101
101
100
100
H
High Pressure Fuel Rails - Remove and Install...... 11
Removal Procedure ............................................ 11
I
Idler Gears (Front) - Remove and Install ............... 98
Important Safety Information ................................... 2
Inlet and Exhaust Valve Guides - Remove and
Install ................................................................... 83
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 84
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 80
Inlet and Exhaust Valves - Remove and Install ..... 81
Inlet Valve Seals - Remove and Install .................. 85
P
Piston Cooling Jets - Remove and Install............ 102
Pistons and Connecting Rods - Assemble ........... 113
Assembly Procedure......................................... 113
Pistons and Connecting Rods - Disassemble ...... 112
Disassembly Procedure .................................... 112
Pistons, Liners, and Connecting Rods - Install..... 115
Installation Procedure ....................................... 115
Pistons, Liners, and Connecting Rods - Remove .. 110
KENR6052-01
137
Index Section
R
Rocker Shaft - Assemble.......................................
Assembly Procedure..........................................
Rocker Shaft - Disassemble ..................................
Disassembly Procedure .....................................
Rocker Shaft and Push Rods - Install....................
Rocker Shaft and Push Rods - Remove................
69
69
68
68
69
69
68
68
T
Table of Contents..................................................... 3
Turbocharger - Install ............................................ 22
Turbocharger - Remove ........................................ 20
V
Valve Cover - Remove and Install .........................
Valve Lifter - Assemble..........................................
Valve Lifter - Disassemble .....................................
Valve Lifter - Install ................................................
Valve Lifter - Remove ............................................
Vibration Damper - Remove and Install.................
67
67
67
71
71
71
71
72
72
70
70
89
90
89
W
Water Pump - Assemble........................................
Assembly Procedure..........................................
Water Pump - Disassemble ...................................
Water Pump - Install ..............................................
Water Pump - Remove ..........................................
28
28
26
26
31
31
26
26
138
Index Section
KENR6052-01
KENR6052-01
139
Index Section
2009 Caterpillar
All Rights Reserved
Cat, Caterpillar, their respective logos, Caterpillar Yellow and the Power edge
trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.
Printed in U.S.A.

Kenr6052 01 01 All PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Kenr6052 01 01 All PDF

Uploaded by

Copyright:

Available Formats

KENR6052-01

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Rocker Shaft - Assemble ..................................... 69

Disassembly and Assembly

Air Starting Motor - Remove

5. Attach a suitable lifting device to air starting

Air Starting Motor - Install

2. Disconnect hose assembly (1) from air starting

7. Turn ON air supply valve.

Electronic Control Module

1. Attach a suitable lifting device to air starting

1. Remove screws (4) and disconnect harness

4. Connect hose assembly (3) to air starting motor

1. Position electronic control module (3). Install the

Fuel Filter Housing - Remove

S/N: ERM; JTL1-Up

Note: Cap tube assemblies, fittings, ports, and any

2. Use Tooling (A) to remove fuel filters (6).

Filter Strap Wrench

3. Remove tube assembly (1) from fuel filter base (2).

1. Turn the fuel supply to the OFF position.

5. Remove bolt (12) and the washer. Disconnect

6. Disconnect hose assembly (9).

3. Remove bolts (8). Disconnect clamps (10).

7. Remove tube assembly (13).

Fuel Filter Housing - Remove

4. Disconnect harness assemblies (1), (4), and (5).

SMCS Code: 1262-011

Fuel Filter Housing - Install

S/N: LAJ; LLM1-Up

SMCS Code: 1262-012

S/N: SSP; B7B1-Up

S/N: EMD; B7C1-Up

S/N: ERM; JTL1-Up

Filter Strap Wrench

Filter Strap Wrench

Fuel Filter Housing - Install

Filter Strap Wrench

1. Position support assembly (10). Install the

1. Install fuel filter base (7). The weight of fuel filter

4. Connect harness assembly (5). Connect hose

6. Turn the fuel supply to the ON position.

Fuel Priming Pump - Remove

3. Remove three bolts (2), the mounts, the spacers,

Contaminants may cause rapid wear and shortened

Refer to Special Publication, NENG2500, Caterpillar

1. Turn the fuel supply to the OFF position.

1. Position bracket assembly (7). Install the washers,

2. Disconnect hose assemblies (4) and (5).

Fuel Transfer Pump - Remove

3. Remove bolts (8). Remove fuel transfer pump (7).

Fuel Transfer Pump - Install

Contaminants may cause rapid wear and shortened

1. Install fuel transfer pump (7). Install bolts (8).

2. Disconnect hose assemblies (1), (2), (3), (5), and

2. Connect harness assembly (4). Connect hose

Do not open the high pressure fuel system without

3. Turn the fuel supply to the ON position.

High Pressure Fuel Rails Remove and Install

Note: Use Tooling (A) to cap tube assemblies,