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SENR9973-01

September 2007

Disassembly and

Assembly400C Industrial Engine

HB (Engine)HD (Engine)HH (Engine)HL (Engine)HM (Engine)

HN (Engine)HP (Engine)HR (Engine)

This document has been printed from SPI². Not for Resale

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SENR9973-01 3Table of Contents

Table of Contents

Disassembly and Assembly Section

Fuel Priming Pump - Remove ................................. 4Fuel Priming Pump - Install ..................................... 4Fuel Filter Base - Remove ..................................... 5Fuel Filter Base - Install ......................................... 6Fuel Injection Lines - Remove and Install .............. 7Fuel Shutoff Solenoid - Remove and Install .......... 9Fuel Injection Pump - Remove ............................ 10Fuel Injection Pump - Install ................................. 11Fuel Injector - Remove ........................................ 12Fuel Injector - Install ............................................ 12Turbocharger - Remove and Install ..................... 13Exhaust Manifold - Remove and Install ............... 15Inlet and Exhaust Valve Springs - Remove and

Install ................................................................... 17Inlet and Exhaust Valves - Remove and Install .... 19

Engine Oil Line - Remove and Install ................... 21Engine Oil Cooler - Remove and Install ............... 23Engine Oil Relief Valve - Remove and Install ....... 24Engine Oil Pump - Remove .................................. 24Engine Oil Pump - Install ...................................... 26Water Pump - Remove ......................................... 28Water Pump - Install ............................................. 30Water Temperature Regulator Housing - Remove and

Install .................................................................. 31Water Temperature Regulator - Remove and Install

............................................................................. 32Flywheel - Remove ............................................... 35Flywheel - Install ................................................... 36Crankshaft Rear Seal - Remove ........................... 37

Crankshaft Rear Seal - Install ............................... 37Flywheel Housing - Remove and Install .............. 39Crankshaft Pulley - Remove and Install ............... 42Crankshaft Front Seal - Remove .......................... 43Crankshaft Front Seal - Install .............................. 43Housing (Front) - Remove .................................... 44Housing (Front) - Disassemble ............................. 45Housing (Front) - Assemble .................................. 47Housing (Front) - Install ........................................ 50Crankcase Breather - Remove and Install ........... 51Valve Mechanism Cover - Remove and Install ..... 54Rocker Shaft and Pushrod - Remove ................... 55Rocker Shaft - Disassemble ................................ 56Rocker Shaft - Assemble ..................................... 57

Rocker Shaft and Pushrod - Install ....................... 59Cylinder Head - Remove ...................................... 60Cylinder Head - Install .......................................... 61Lifter Group - Remove and Install ......................... 63Camshaft - Remove .............................................. 64Camshaft - Disassemble ....................................... 65Camshaft - Assemble ........................................... 66Camshaft - Install .................................................. 66Engine Oil Pan - Remove and Install ................... 67Pistons and Connecting Rods - Remove .............. 68Pistons and Connecting Rods - Disassemble ....... 69Pistons and Connecting Rods - Assemble ........... 71Pistons and Connecting Rods - Install .................. 73Connecting Rod Bearings - Remove .................... 74

Connecting Rod Bearings - Install ........................ 75Crankshaft Main Bearings - Remove .................... 76Crankshaft Main Bearings - Install ........................ 77Crankshaft - Remove ............................................ 78Crankshaft - Install ................................................ 80Bearing Clearance - Check ................................... 81Coolant Temperature Switch - Remove and

Install ................................................................... 82Engine Oil Pressure Switch - Remove and Install

............................................................................. 84Glow Plugs - Remove and Install ......................... 86V-Belts - Remove and Install ................................ 86Fan - Remove and Install ..................................... 87

Alternator - Remove and Install ........................... 91Electric Starting Motor - Remove and Install ..... 101

Index Section

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


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SENR9973-01 5Disassembly and Assembly Section

g01129954Illustration 2

Typical example

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

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

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

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

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

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

6. Loosely install the hose clamps to the fuel lines.

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

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

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

i02186242

Fuel Filter Base - Remove

Removal Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

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

Dispose of all fluids according to local regulations andmandates.


Typical example

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


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6 SENR9973-01Disassembly and Assembly Section

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

2. Remove the fuel filter element (4). Refer to

Operations and Maintenance Manual, “FuelSystem Filter - Replace”.

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

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

5. Remove the fuel fi lter base (3) from the engine.

i02186227

Fuel Filter Base - Install

Installation Procedure




Typical example

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

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

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

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

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

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


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End By:

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

i02801636

Fuel Injection Lines - Removeand Install

Removal Procedure


Contaminants may cause rapid wear and shortened

component life.

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


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

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

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

Note: The removal procedure is similar for the twocylinder, the three cylinder and the four cylinder

engines. The illustrations show the 404C-22 and404C-22T engines.


404C-22 and 404C-22T engines

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

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

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

Note: Place identification marks on all tube

assemblies for installation. Plug all tube assembliesin order to prevent contamination.

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

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

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

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

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


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404C-22 and 404C-22T engines

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

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

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

injectors (7).

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

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

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

Note: If new fuel injection lines have been installed,

do not make any adjustments to the engine controls.Check the maximum engine speed at no load. Refer to Testing and Adjusting, “Engine Speed - Check”for more information.

i02207974

Fuel Shutoff Solenoid -Remove and Install

Removal Procedure



NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be prepared

to collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.



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

2. Remove fuel shutoff solenoid (1) from the fuel

injection pump housing by rotating the fuel shutoff solenoid in a counterclockwise direction.

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





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

2. Install fuel shutoff solenoid (1) into the fuel

injection pump housing by rotating the fuel shutoff solenoid in a clockwise direction. Tighten the fuelshutoff solenoid to a torque of 17.5 N·m (12.9 lb ft).

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

i02797470

Fuel Injection Pump - Remove

Removal ProcedureStart By:

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

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



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

ponent containing fluids.


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


Typical example


Typical example

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

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


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

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

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

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

i02801637

Fuel Injection Pump - Install




NOTICE

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


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

engine.

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


Typical example

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

Injection Pump”.


Typical example

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

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

5. Install the setscrews (4) and the nuts (2) that

fasten the fuel injection pump to the cylinder block.

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

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


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End By:

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

b. Install the fuel injection lines. Refer to Disassembly

and Assembly, “Fuel Injection Lines - Removeand Install”.

i02801638

Fuel Injector - Remove

Removal Procedure

Start By:

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



NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-

ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.



Typical example

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

2. Remove the seat washers (2) from the cylinder head. Discard the old seat washers.

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

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

i02801639

Fuel Injector - Install


NOTICE

Keep all parts clean from contaminants.



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Typical example

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

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

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

404C-22T engines have one seat washer.

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

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

4. Install the fuel injector (1) into the cylinder head.

Use a deep socket to tighten the fuel injector to atorque of 64 N·m (47 lb ft).

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

End By:

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

i02186260

Turbocharger - Remove andInstall

Removal procedure



NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be prepared

to collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.


g01114005Illustr ation 17

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

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


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

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

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

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

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

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

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

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

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

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

Installation procedure



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


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


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


Typical example

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

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

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

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

3. Remove the exhaust manifold (4) from the cylinder head (1).

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

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

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




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


Typical example

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

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

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

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

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

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

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

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

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


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i02187986

Inlet and Exhaust ValveSprings - Remove and Install

Removal Procedure

Table 1

Required Tools

Part Number Part Description Qty

21825666 Valve Spring Compressor 1

27610235 Adapter 1

Start By:

a. Remove the rocker shaft assembly. Refer to

Disassembly and Assembly, “Rocker Shaft andPushrod - Remove”.



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

springs.

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

Note: Ensure that the appropriate piston is at topdead center before the valve spring is removed.Failure to ensure that the piston is at top dead center

may allow the valve to drop into the cylinder bore.

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

Make sure to wear all necessary protective equip-ment.

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

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

g01015085

Illustration 23Typical example

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

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

b. Compress the valve spring (5) suf ficiently inorder to open the valve only. Do not compressthe valve spring so that the valve keepers (3)

could be removed from the recess in the valvestem or so that the valve stem seal (not shown)could be damaged.

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

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

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

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


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NOTICEDo not turn the crankshaft while the valve springs areremoved.

2. Use the valve spring compressor (1) and the

adapter (2) in order to compress the valve spring(5). Remove the valve keepers (3).

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


Table 2

Required Tools



27610235 Adapter 1



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

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

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


Typical example

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

2. Install the valve spring retainer (4).

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


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

NOTICEDo not turn the crankshaft while the valve springs areremoved.

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

(3) are properly installed.

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


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End By:

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

i02187989

Inlet and Exhaust Valves -Remove and Install

Removal Procedure

Table 3

Required Tools



27610235 Adapter 1

Start By:

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



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

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

2. Place an identification mark on the heads of the

valves for installation purposes.

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

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

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





Typical example

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


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

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


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Typical example

7. Remove the valve spring retainer (4).

8. Remove the valve spring (5).

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

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

11. Remove the valve stem seals (6).

12. Carefully turn over the cylinder head.

13. Remove the valves (7).


Table 4

Required Tools



27610235 Adapter 1



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

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

2. Inspect all of the valve seats for wear and for

damage. Refer to Specifications, “Cylinder HeadValves” and refer to Testing and Adjusting, “ValveDepth - Inspect ” for further information.

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


Typical example

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

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

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

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

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

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


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9. Install the valve spring retainer (4).

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




Typical example


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


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

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

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

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

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

15. Place the cylinder head on a suitable support.Ensure that the heads of the valves are notobstructed. Gently strike the top of the valves witha soft hammer in order to ensure that the valve

keepers (3) are properly installed.

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

End By:

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

i02801641

Engine Oil Line - Remove andInstall

Removal Procedure


Typical example

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


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


Typical example

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

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



Typical example

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

2. Position the banjo bolt (3) and the new washers

(4) on the oil line (1). Install the oil line to thecylinder block.


Typical example


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

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

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

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

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

i02186236

Engine Oil Cooler - Remove

and Install

Removal Procedure



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


1. Drain the coolant from the cooling system intoa suitable container. Drain the engine oil into asuitable container. Refer to the Operation and

Maintenance Manual for the procedure on drainingthe coolant and the engine oil.


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

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

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

cylinder block (7).

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




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

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

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


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

5. Lubricate the O-ring of the oil filter element (5) withclean engine oil. Install the new oil filter element tothe oil cooler body (4). Tighten the oil filter element

by hand. Do not use a strap wrench to tighten theoil filter element.

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

i02182334

Engine Oil Relief Valve -Remove and Install

Removal Procedure



NOTICE

Care must be taken to ensure thatfl

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



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

2. Remove the O-ring (1) from the engine oil relief valve. Discar d the O-ring.



Contaminants may cause rapid wear and shortenedcomponent lif e.


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

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

engine oil.

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

i02182152

Engine Oil Pump - Remove

Removal Procedure

Start By:

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




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

NOTICE

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


Engine Oil Pump


Typical example




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

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

• Collar (8)

• Spring (7)

• Shim (6)

• Oil pump cover (5)

• Inner rotor (4)

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

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

5. Inspect all the components for wear or damage. Any components that are worn or damaged should

be replaced with new parts.

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

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

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


Typical example

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

c. Remove the oil tube (11) from the cylinder block.

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


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Idler Hub


Typical example

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

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

i02801642

Engine Oil Pump - Install


Table 5

Required Tools

ToolPart

Number Part Description Qty

A(1) 21825624 Alignment Tool 1



B - Multipurpose Grease 1

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



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

Idler Hub


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

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

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

4. Remove Tooling (A).


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Engine Oil Pump



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

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

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

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

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

Personal injury can result from the release of thespring force.

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

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

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

• Oil pump cover (5)

• Shim (6)

• Spring (7)

• Collar (8)

Refer to Illustration 40.

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


Checking end play by using a feeler gauge

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

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


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

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

block.

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

End By:

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

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

i02801654

Water Pump - Remove

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

Start By:

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

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






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

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


Typical example

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


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Typical example

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

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

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

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

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

Start By:

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

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







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


typical example

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


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Typical example

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

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

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

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

i02801657

Water Pump - Install

Installation Procedure (403C-11,403C-15, 403C-17, 404C-15, 404C-22

and 404C-22T Engines)NOTICE



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


Typical example

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

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


Typical example

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

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


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End By:

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

b. Install the pulley, the adapter and the fan. Refer to

Disassembly and Assembly, “Fan - Remove andInstall”.

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

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



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

g01124046

Illustration 50Typical example

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

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


Typical example

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

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

End By:

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

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

Install”.

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

i02182980

Water Temperature Regulator Housing - Remove and Install

Removal ProcedureNOTICE




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


Typical example

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

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

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




1. Clean the mating surfaces of the cylinder head. Clean the mating surfaces of the water temperature regulator housing.


Typical example

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

3. Install the water temperature regulator housing

(2) to the cylinder head.

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

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

i02801658

Water Temperature Regulator -Remove and Install

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


Contaminants may cause rapid wear and shortened

component life.


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Typical example

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

Spring for ce will be released when covers are re-moved.

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

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

3. Remove the outlet connection (4) for the water temperature regulator.

4. Remove the joint (3).

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

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

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



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


1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Refer to Operation and Maintenance Manual, “Refill

Capacities” for the approximate capacity of thecooling system.


Typical example

2. Remove the setscrews (1).


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3. Remove the outlet connection (2) for the water temperature regulator.

Note: Identify the orientation of the outlet connectionfor installation.

4. Remove the joint (3).

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

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

Installation Procedure (402C-05

and 403C-07 engines)



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





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

Note: Install the water temperature regulator with the

jiggle pin in the vertically upward position.

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

4. Install the outlet connection (4) to the cylinder head.

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

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

7. Fill the cooling system with coolant to the correct

level. Refer to Operation and MaintenanceManual, “Refill Capacities” for more information.

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



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


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

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

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

Note: Ensure the correct orientation of the outletconnection.

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

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

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

i02183594

Flywheel - Remove

Removal Procedure

Start By:

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



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


Typical example

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

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

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

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

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

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

6. Inspect the flywheel ring gear (5) and the flywheel(2) for wear or damage. If the flywheel ring gear or

the flywheel is worn or damaged, use new partsfor replacement.


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Typical example

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

i02183590

Flywheel - Install




Always wear protective gloves when handlingparts that have been heated.


Typical example

1. Thoroughly clean the flywheel housing. Inspectthe crankshaft rear seal for leaks. If there areany oil leaks refer to Disassembly and Assembly,

“Crankshaft Rear Seal - Remove”.

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

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

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

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

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

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


Typical example


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

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

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

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

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

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

8. Use a suitable tool to prevent the flywheel (1) from

rotating. Tighten the setscrews (5) to a torque of 73.5 N·m (54.2 lb ft).

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

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

End By:

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

i02183600

Crankshaft Rear Seal - Remove

Removal Procedure

Start By:

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






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


Typical example

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

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

i02801659

Crankshaf t Rear Seal - Install

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

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


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Typical example

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

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

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

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

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

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


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

8. Align the back plate (6) to the dowels (3) and

install the back plate to the cylinder block (1).

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

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

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

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

End By:

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

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

i02801660

Flywheel Housing - Remove

and Install

Removal Procedure (Engines withFlywheel Housing and Back plate)

Start By:

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



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

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


Typical example

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

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

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

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


Typical example

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


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Removal Procedure (Engines withFlywheel Housing)

Start By:

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



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

1. Support the engine with a suitable lifting device or

support the engine on blocks that are positionedon a flat level surface.

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


Typical example

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


Typical example

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

Installation Procedure (Engineswith Flywheel Housing and Backplate)




Typical example


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1. Clean the rear face of the back plate (2) and thefaces of the flywheel housing (8). Inspect thecrankshaft rear seal (not shown) for leaks. Inspectthe dowels (6) for damage. If the crankshaftrear seal or the dowels are damaged, use newparts for replacement. Refer to Disassembly and

Assembly, “Crankshaft Rear Seal - Remove” and

Disassembly and Assembly, “Crankshaft Rear Seal - Install”.


Typical example

2. Use the lifting device (9) to align the flywheel

housing (8) to the dowels (6). Install the fl

ywheelhousing to the back plate.

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

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

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

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

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

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

End By:

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

Installation Procedure (Engineswith Flywheel Housing)




Typical example

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

“Crankshaft Rear Seal - Install”.


Typical example

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


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

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

For 403C-11 and 404C-15 engines, tighten the

setscrews to a torque of 50 N·m (37 lb ft).

For 403C-15 and 403C-17 engines, tighten thesetscrews to a torque of 25 N·m (19 lb ft).

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

End By:

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

i02801663

Crankshaft Pulley - Removeand Install

Removal Procedure

Table 6

Required Tools

Part Number Description Qty

21825619 Puller 1

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


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


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

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



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

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

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

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

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

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


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

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

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

i02200446

Crankshaft Front Seal -Remove

Removal Procedure



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

nent containing fl

uids.


Remove the Front Oil Seal that is installed

in the Engine

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

Remove the Front Oil Seal from a

Disassembled Front Cover

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

i02187983

Crankshaft Front Seal - Install





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

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

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

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

4. Use a suitable tool (3) to install the new crankshaft

front seal (2).

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

End By:

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


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i02186336

Housing (Front) - Remove

Removal Procedure

Start By:

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

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



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



Typical example

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

2. Turn the mechanical stop lever (3) to the full

clockwise position so that the spring is held under tension.

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

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

4. Remove the joint (not shown) from the cylinder block (6) or from the front housing (4). Discard the

joint.

5. Inspect the front housing assembly (4) for wear

or damage. If the front housing assembly isdamaged, use new parts for replacement.


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i02186302

Housing (Front) - Disassemble

Disassembly Pr ocedure

Start By:

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



NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fl

Documents

400c