Perkins 1106D Installation instructions

SENR9983
October 2005
Disassembly and
Assembly
1106D Industrial Engine
PJ(Engine)

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.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins 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. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

SENR9983 3
Table of Contents
Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump - Remove and Install .............. 4
Fuel Filter Base - Remove and Install (Secondary
Fuel Filter) ............................................................. 7
Fuel Transfer Pump - Remove ................................ 8
Fuel Transfer Pump - Install .................................. 10
Fuel Injection Lines - Remove .............................. 11
Fuel Injection Lines - Install ................................. 12
Fuel Manifold (Rail) - Remove and Install ............. 14
Fuel Injection Pump - Remove ............................ 16
Fuel Injection Pump - Install ................................ 18
Fuel Injection Pump Gear - Remove .................... 22
Fuel Injection Pump Gear - Install ........................ 23
Electronic Unit Injector - Remove ......................... 25
Electronic Unit Injector - Install ............................. 28
Turbocharger - Remove ........................................ 32
Turbocharger - Disassemble ................................ 35
Turbocharger - Assemble .................................... 35
Turbocharger - Install ............................................ 36
Wastegate Solenoid - Remove and Install ............ 40
Exhaust Manifold - Remove and Install ............... 41
Exhaust Elbow - Remove and Install ................... 45
Inlet Manifold - Remove and Install ..................... 46
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 48
Inlet and Exhaust Valves - Remove and Install .... 52
Engine Oil Filter Base - Remove and Install ........ 55
Engine Oil Cooler - Remove ................................. 56
Engine Oil Cooler - Install ..................................... 58
Engine Oil Relief Valve - Remove and Install ....... 61
Engine Oil Pump - Remove .................................. 63
Engine Oil Pump - Install ...................................... 64
Water Pump - Remove ......................................... 65
Water Pump - Install ............................................. 66
Water Temperature Regulator - Remove and Install
............................................................................. 67
Flywheel - Remove ............................................... 69
Flywheel - Install ................................................... 70
Crankshaft Rear Seal - Remove ........................... 71
Crankshaft Rear Seal - Install ............................... 72
Crankshaft Wear Sleeve (Rear) - Remove and
Install ................................................................... 75
Flywheel Housing - Remove and Install .............. 76
Vibration Damper and Pulley - Remove .............. 81
Vibration Damper and Pulley - Install .................. 82
Crankshaft Front Seal - Remove and Install ......... 84
Crankshaft Wear Sleeve (Front) - Remove and
Install ................................................................... 85
Front Cover - Remove and Install ......................... 86
Gear Group (Front) - Remove and Install ............. 88
Idler Gear - Remove ............................................. 91
Idler Gear - Install ................................................. 93
Housing (Front) - Remove .................................... 96
Housing (Front) - Install ........................................ 98
Accessory Drive - Remove and Install ............... 100
Crankcase Breather - Remove ........................... 101
Crankcase Breather - Install ............................... 104
Valve Mechanism Cover - Remove and Install ... 108
Valve Mechanism Cover Base - Remove and
Install ................................................................. 109
Rocker Shaft and Pushrod - Remove .................. 111
Rocker Shaft - Disassemble ............................... 112
RockerShaft-A
ssemble .................................... 113
Rocker Shaft and Pushrod - Install ...................... 114
Cylinder Head - Remove ..................................... 116
Cylinder Head - Install ......................................... 118
Lifter Group - Remove and Install ....................... 122
Camshaft - Remove and Install ......................... 123
Camshaft Gear - Remove and Install ................ 125
Camshaft Bearings - Remove and Install .......... 127
Engine Oil Pan - Remove .................................. 129
Engine Oil Pan - Install ...................................... 131
Piston Cooling Jets - Remove and Install ........... 138
Pistons and Connecting Rods - Remove ............ 139
Pistons and Connecting Rods - Disassemble ..... 140
Pistons and Connecting Rods - Assemble ......... 142
Pistons and Connecting Rods - Install ................ 144
Connecting Rod Bearings - Remove (Connecting
rods in position) ................................................. 145
Connecting Rod Bearings - Install (Connecting rods
in position) ......................................................... 146
Crankshaft Main Bearings - Remove and Install
(Crankshaft in position) ..................................... 148
Crankshaft - Remove .......................................... 151
Crankshaft - Install .............................................. 152
Crankshaft Timing Ring - Remove and Install .... 155
Crankshaft Gear - Remove and Install .............. 156
Bearing Clearance - Check ................................. 158
Crankshaft Position Sensor - Remove and
Install ................................................................. 159
Coolant Temperature Sensor - Remove and
Install ................................................................. 159
Engine Oil Pressure Sensor - Remove and Install
........................................................................... 161
Position Sensor (Fuel Injection Pump) - Remove and
Install ................................................................. 162
Fuel Pressure Sensor - Remove and Install ....... 163
Boost Pressure Sensor - Remove and Install ..... 164
Inlet Air Temperature Sensor - Remove and
Install ................................................................. 165
Glow Plugs - Remove and Install ....................... 166
Alternator Belt - Remove and Install .................. 167
Fan - Remove and Install ................................... 168
Fan Drive - Remove and Install ......................... 169
Electronic Control Module - Remove and Install .. 170
ECM Mounting Bracket - Remove and Install ..... 172
Alternator - Remove ............................................ 175
Alternator - Install ................................................ 176
Electric Starting Motor - Remove and Install ..... 177
Index Section
Index ................................................................... 178

4SENR9983
Disassembly and Assembly Section
Disassembly and Assembly
Section
i02295884
FuelPrimingPump-Remove
and Install
Removal Procedure (Manual
Priming Pump)
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Isolate the fuel supply.
2. Makeatemporaryidentificationmarkonthe
plastic tube assemblies (1) in order to show the
correct position of the tube assemblies.
3. Place a suitable container below the fuel priming
pump in order to catch any fuel that might
be spilled. Drain the primary filter (7). Refer
to Operation and Maintenance Manual, “Fuel
System Primary Filter (Water Seperator) Element
-Replace”.
Note: Clean up any spillage of fuel immediately.
g01181971
Illustration 1
Typical example
4. Disconnect the plastic tube assemblies (1). Plug
the tube assemblies with new plugs. Cap the open
connectors (2) on the fuel priming pump with new
caps.
5. Remove the primary filter (7) from the fuel priming
pump (4). Refer to Operation and Maintenance
Manual, “Fuel System Primary Filter (Water
Seperator) Element - Replace”.
6. Remove the two setscrews (6) from the fuel
priming pump (4). Remove the fuel priming pump
(4) from the mounting bracket.
7. If necessary, follow Steps 7.a through 7.c in order
to disassemble the fuel priming pump (4).
a. Remove the connectors (2) from the fuel
priming pump (4).
b. Remove the plugs (5) from the fuel priming
pump (4).
c. Remove the O-ring seals (3) from the
connectors (2) and the plugs (5). Discard the
O-ring seals.

SENR9983 5
Disassembly and Assembly Section
Removal Procedure (Electric Fuel
Priming Pump)
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Isolate the fuel supply.
g01186418
Illustration 2
Typical example
2. Isolate the electrical supply.
3. Disconnect the electrical lead (3) for the electric
priming pump (4).
4. Makeatemporaryidentificationmarkonthe
plastic tube assemblies (1) and (2) in order to
show the correct position of the tube assemblies.
5. Disconnect the plastic tube assemblies (1) and (2).
Plug the tube assemblies with new plugs. Cap the
ports in the fuel priming pump (4) with new caps.
6. Remove the four setscrews (5) from the electric
priming pump (4).
7. Remove the electric priming pump (4) from the
mounting bracket.
Installation Procedure (Manual
Priming Pump)
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Ensure that the fuel priming pump (4) is clean and
free from wear or damage. If necessary, replace
the fuel priming pump.
g01181971
Illustration 3
Typical example
2. If necessary, follow Steps 2.a through 2.d in order
to assemble the fuel priming pump (4).
a. Install new O-ring seals (3) to the connectors
(2) and to the plugs (5).
b. Install the connectors (2) to the fuel priming
pump (4).
c. Install the plugs (5) to the fuel priming pump (4).

6SENR9983
Disassembly and Assembly Section
d. Tighten the plugs and the connectors to a
torque of 20 N·m (14 lb ft).
3. Position the fuel priming pump (4) on the mounting
bracket. Install the two setscrews (6) to the fuel
primingpump.Tightenthesetscrewstoatorque
of 44 N·m (32 lb ft).
4. Remove the plugs from the plastic tube
assemblies. Remove the caps from the
connectors.
5. Connect the plastic tube assemblies (1) to the
connectors (2).
Note: Ensure that the plastic tube assemblies are
installed in the original positions.
6. Install a new primary filter (7) to the fuel priming
pump (4). Refer to Operation and Maintenance
Manual, “Fuel System Primary Filter (Water
Seperator) Element - Replace”.
7. Restore the fuel supply.
8. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime”.
Installation Procedure (Electric
Fuel Priming Pump)
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Ensure that the electric priming pump (4) is clean
and free from wear or damage. If necessary,
replace the electric priming pump.
g01186418
Illustration 4
Typical example
2. Position the electric priming pump (4) on the
mounting bracket. Install the four setscrews (5) to
the electric priming pump (4).
3. Tighten the setscrews (5) to a torque of 9 N·m
(79 lb in).
4. Remove the plugs from the plastic tube
assemblies. Remove the caps from the electric
priming pump.
5. Connect the plastic tube assemblies (1) and (2) to
the electric priming pump (4).
Note: Ensure that the plastic tube assemblies are
installed in the original positions.
6. Connect the electrical lead (3) for the electric
priming pump (4).
7. Restore the electrical supply.
8. Restore the fuel supply.
9. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime”.

SENR9983 7
Disassembly and Assembly Section
i02295889
Fuel Filter Base - Remove and
Install
(Secondary Fuel Filter)
Removal Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Isolate the fuel supply.
g01165584
Illustration 5
Typical example
2. Make temporary identification marks on the plastic
tube assemblies (3), (4) and (5) in order to show
the correct position of the tube assemblies.
3. Place a suitable container below the fuel filter base
in order to catch any fuel that might be spilled.
Note: Clean up any spillage of fuel immediately.
4. Disconnect the plastic tube assemblies (3), (4)
and (5) from the fuel filter base (1). Plug the plastic
tube assemblies with new plugs. Cap the ports in
the fuel filter base with new caps.
5. Remove the fuel filter (6). Refer to Operation and
Maintenance Manual, “Fuel System Secondary
Filter - Replace”.
6. Remove the two setscrews (2) from the fuel filter
base (1). Remove the fuel filter base from the
mounting bracket.
Note: Do not disassemble the fuel filter base.
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Ensure that the fuel filter base (1) is clean and free
from damage. If necessary, replace the complete
fuel filter base and filter assembly.
g01165584
Illustration 6
Typical example

8SENR9983
Disassembly and Assembly Section
2. Position the fuel filter base (1) on the mounting
bracket. Install the setscrews (2). Tighten the
setscrews to a torque of 44 N·m (32 lb ft).
3. Remove the plugs from the plastic tube
assemblies. Remove the caps from the ports in
the fuel filter base.
NOTICE
Ensure that the plastic tube assemblies are installed
in the original positions. Failure to connect the plastic
tube assemblies to the correct ports will allow contam-
ination to enter the fuel system. Contaminated fuel will
cause serious damage to the engine.
4. Connect the plastic tube assemblies (3), (4) and
(5) to the fuel filter base (1).
Note: Ensure that the plastic tube assemblies are
installed in the original positions. Failure to connect
the plastic tube assemblies to the correct ports
will allow contamination to enter the fuel system.
Contaminated fuel will cause serious damage to the
engine.
5. If necessary, install a new fuel filter (6) to the
fuel filter base (1). Refer to Operation and
Maintenance Manual, “Fuel System Secondary
Filter - Replace” for the correct procedure.
6. Restore the fuel supply.
End By:
a. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime”.
i02296828
Fuel Transfer Pump - Remove
Removal Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Isolate the fuel supply.
2. Place a suitable container below the fuel transfer
pump (1) in order to catch any fuel that might be
spilled.
Note: Clean up any spillage of fuel immediately.

SENR9983 9
Disassembly and Assembly Section
g01162545
Illustration 7
Typical example
3. Remove the plastic tube assembly (2) from the
fuel transfer pump (1).
4. Disconnect the plastic tube assembly (3) from the
outlet of the fuel transfer pump (1).
5. Remove the connector (4) from the fuel transfer
pump (1). Remove the O-ring seal (not shown)
from the connector (4). Discard the O-ring seal.
If necessary, remove the connector (7) from the
fuel transfer pump (1). Remove the O-ring seal
(not shown) from the connector (7). Discard the
O-ring seal.
6. Remove the tube assembly (6) for the fuel return
from the fuel transfer pump and the cylinder head.
Note: Disconnect the tube assembly at the fuel
transfer pump first in order to drain the fuel from the
cylinder head.
7. Remove the tube assembly (5) for the engine oil
supply from the fuel injection pump (8).
8. Plug or cap all open ports and tube assemblies
immediately with new plugs or caps.
9. Use an allen wrench with a ball end in order to
remove the five allen head screws (9) that secure
the fuel transfer pump to the fuel injection pump
(8).
g01162543
Illustration 8
10. Remove fuel transfer pump (1) from the fuel
injection pump (8).
Note: Do not remove the dowels (10) from the fuel
injection pump.
g01162544
Illustration 9
11. Remove the O-ring seal (11) from the fuel transfer
pump (1). Discard the O-ring seal.

10 SENR9983
Disassembly and Assembly Section
i02296829
Fuel Transfer Pump - Install
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Ensure that the mating faces of the fuel injection
pump (8) and the fuel transfer pump (1) are clean
and free from damage.
g01162544
Illustration 10
2. Install a new O-ring seal (11) to fuel transfer pump
(1). Lubricate the O-ring seal with clean engine oil.
g01162543
Illustration 11
3. Align the holes in the fuel transfer pump (1) with
thedowels(10)inthefuelinjectionpump(8).
Install the fuel transfer pump to the fuel injection
pump.
g01162545
Illustration 12
Typical example
4. Use an allen wrench with a ball end to install the
five allen head screws (9). Tighten the allen head
screws toatorqueof30N·m(22lbft).
5. Remove the plugs and the caps from the ports
and tube assemblies.

SENR9983 11
Disassembly and Assembly Section
6. Install the tube assembly (5) for the engine oil
supply to the fuel injection pump (8) and to the
cylinder block.
7. Install the tube assembly (6) for the fuel return to
the fuel transfer pump (1) and to the cylinder head.
8. Install a new O-ring seal (not shown) to the
connector (4). Install the connector (4) to the fuel
transfer pump (1). Tighten the connector to torque
of 15 N·m (11 lb ft).
9. If necessary, install a new O-ring seal (not shown)
to the connector (7) and install the connector (7) to
the fuel transfer pump (1). Tighten the connector
to torque of 15 N·m (11 lb ft).
10. Connect the plastic tube assembly (3) to the
outlet of the fuel transfer pump (1).
11. Install the plastic tube assembly (2) to the fuel
transfer pump (1).
12. Restore the fuel supply.
13. Remove the air from the fuel system. Refer to
Testing and Adjusting Manual, “Fuel System -
Prime”.
i02295890
Fuel Injection Lines - Remove
Removal Procedure
Table 1
Required Tools
Tool Part
Number Part Name Qty
AU5MK1124 Cap Kit 1
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Isolate the fuel supply.
2. Isolate the electrical supply.
g01178882
Illustration 13
Typical example
3. Remove the two plastic clamps (2) from the fuel
injection lines (1). Discard the plastic clamps.
4. Slide the dust seal (3) from the nut on the fuel
injection line (1).
5. Disconnect the fuel injection line (1) at the
electronic unit injector (4).
6. Disconnect the fuel injection line (1) at the fuel
manifold (5).
7. Remove the fuel injection line (1). Discard the fuel
injection line.
Note: Clean up any spillage of fuel immediately.

12 SENR9983
Disassembly and Assembly Section
8. Plug the open port in the fuel manifold (5)
immediately. Use Tooling (A) in order to plug the
open port in the fuel manifold.
9. Remove the seal (6) from the electronic unit
injector (4) and the base of the valve mechanism
cover (not shown).
Note: The seal can be damaged by contact with fuel.
10. Plug the open port in electronic unit injector (4)
immediately. Use Tooling (A) in order to plug the
open port in the electronic unit injector.
11. Repeat Steps 4 through 11 in order to remove
the remaining fuel injection lines from the fuel
manifold to the electronic unit injectors.
g01198424
Illustration 14
Typical Example
12. Disconnect the harness assembly (9) from the
fuel injection pump (8). Slide the locking tab
(10) into the unlocked position. Disconnect the
harness assembly (9) from the position sensor
(11). Position the harness assembly (9) so that
the harness assembly is clear of the fuel injection
line (7).
g01208398
Illustration 15
g01208399
Illustration 16
Assembly of the tube clip
13. Remove the fasteners (12) from the three tube
clips (13) that secure the fuel injection line (7).
Loosen the three allen head screws (14). Position
the tube clips in order to allow removal of the fuel
injection line.
14. Disconnect the fuel injection line (7) at the fuel
injection pump (8).
15. Disconnect the fuel injection line (7) at the fuel
manifold (5).
16. Plug all open ports immediately. Use Tooling (A)
in order to plug the open ports in the fuel manifold
(5) and in the fuel injection pump (8).
17. Remove the fuel injection line (7).
Note: Clean up any spillage of fuel immediately.
18. Remove the allen head screws (14) and the
assemblies of the three tube clips (13) from fuel
injection line (7). Discard the fuel injection line.
i02295912
Fuel Injection Lines - Install
Installation Procedure
Table 2
Required Tools
Tool Part
Number Part Name Qty
A27610294 Injector Pipe Nut Tool 1

SENR9983 13
Disassembly and Assembly Section
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
Note: The following procedure should be adopted
in order to install the fuel injection lines when the
electronic unit injectors or the fuel manifold have
not been removed. If the electronic unit injectors
or the fuel manifold have been removed, refer to
Disassembly and Assembly Manual, “Electronic Unit
Injector-I
nstall” and Disassembly and Assembly
Manual, “Fuel Manifold - Install” for more information.
g01208399
Illustration 17
Assembly of the tube clip
g01208398
Illustration 18
1. Loosely install the assemblies of the three tube
clips (13) and the allen head screws (14) to the
fuel injection line (7).
2. Place the fuel injection line (7) in position.
3. Remove the caps from the port in the fuel injection
pump (8) and from the appropriate port in the fuel
manifold (5). Remove the caps from the new fuel
injection line (7).
4. Loosely connect the nuts at both ends of the fuel
injection line (7), to the fuel manifold (5) and to
the fuel injection pump (8). Ensure that the ends
of the fuel injection line are correctly seated in the
fuel injection pump and in the fuel manifold.
5. Use Tooling (A) to tighten the nuts on the fuel
injectionline(7)toatorqueof30N·m(22lbft).
6. Install the setscrews (12) for the three tube clips
(13) that secure the fuel injection line (7). Tighten
the setscrews (12) to a torque of 22 N·m (16 lb ft).
Tighten the M5 allen head screws (14) to a torque
of 10 N·m (89 lb in). Ensure that fuel injection line
does not contact any other engine component.
g01198424
Illustration 19
Typical example
7. Connect the harness assembly (9) to the position
sensor (11). Slide the locking tab (10) into the
locked position. Connect the harness assembly
(9) to the fuel injection pump (8).

14 SENR9983
Disassembly and Assembly Section
g01178882
Illustration 20
Typical example
8. Thoroughly clean the seal (6). Inspect the seal for
damage. If necessary, replace the seal.
Note: The seal can be damaged by contact with
fuel. If the seal has been in contact with fuel for a
prolonged period, the seal should be replaced.
9. Install the seal (6) to the electronic unit injector
(4). Ensure that the flange on the seal is flush with
the valve mechanism cover base.
10. Remove the caps from the new fuel injection line
(1). Ensure that a new dust seal (3) is installed
to the fuel injection line.
11. Remove the caps from the electronic unit injector
(4) and from the appropriate port in the fuel
manifold (5).
12. Loosely connect the nuts at both ends of the fuel
injection line (1), to the electronic unit injector (4)
and to the appropriate port in the fuel manifold
(5). Ensure that the ends of the fuel injection line
are correctly seated in the electronic unit injector
andinthefuelmanifold.
13. Use Tooling (A) to tighten the nuts on the fuel
injectionline(1)toatorqueof30N·m(22lbft).
Slide the dust seal (3) into position over the nut on
the fuel injection line. Ensure that the dust seal (3)
is in contact with the seal (6).
14. Follow Steps 8 through 13 in order to install the
remaining fuel injection lines.
15. Install two new clamps (2) to the fuel injection
lines. Ensure that the clamps are fully closed in
order to retain the fuel injection lines.
Note: Ensure that fuel injection lines do not contact
any other engine component.
16. Restore the fuel supply.
17. Restore the electrical supply.
18. Remove the air from the fuel system. Refer to
the Operations and Maintenance Manual, “Fuel
System - Prime”.
i02403286
Fuel Manifold (Rail) - Remove
and Install
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly Manual, “Fuel
Injection Lines - Remove”.
b. If necessary, remove the fuel pressure sensor.
Refer to Disassembly and Assembly Manual,
“Fuel Pressure Sensor - Remove and Install”.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
elspraymaycauseafirehazard.Failuretofol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.

SENR9983 15
Disassembly and Assembly Section
g01190733
Illustration 21
The fuel manifold is shown with fuel injection lines in position.
1. If the fuel sensor (4) has not been removed from
the fuel manifold (1), slide the locking tab (3) into
the unlocked position. Disconnect the plug on
the harness assembly (6) from the fuel pressure
sensor (4).
2. Disconnect the tube assembly (5) from the fuel
pressure relief valve on the fuel manifold (1).
Immediately cap the open port in the fuel manifold
(1) with a new cap. Immediately plug the open end
of the tube assembly (5) with a new plug.
3. Remove the three setscrews (2) from the fuel
manifold (1).
4. Remove the fuel manifold (1) from the mounting
bracket (7).
Installation Procedure
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Ensure that all ports on the fuel manifold are
capped. Ensure that the fuel manifold is externally
clean and free from damage.
Note: Do not install a fuel manifold that has not
been capped. All caps must be left in place until the
fuel injection lines or the fuel pressure sensor are
installed.
g01190733
Illustration 22
The fuel manifold is shown with fuel injection lines in position.
2. Position the fuel manifold (1) on the mounting
bracket (7).
3. Install the three setscrews (2) to the fuel manifold
(1)fingertight.
4. Install a new set of fuel injection lines and seals.
Refer to Disassembly and Assembly Manual,
“Fuel Injection Lines - Install” for more information.
5. Tighten the setscrews (2) to a torque of 22 N·m
(16 lb ft).
6. Removetheplugfromthetubeassembly(5).
Remove the cap from the appropriate port in the
fuel manifold (1). Connect the tube assembly
(5) to the fuel pressure relief valve on the fuel
manifold (1).
7. If the fuel pressure sensor (4) was not removed
from the fuel manifold (1), connect the plug on
the harness assembly (6) to the fuel pressure
sensor (4). slide the locking tab (3) into the locked
position.

16 SENR9983
Disassembly and Assembly Section
If the fuel pressure sensor (4) was removed from
the fuel manifold (1), install the fuel pressure
sensor (4) and a new sealing washer. Refer
to Disassembly and Assembly Manual, “Fuel
Pressure Sensor - Revove and Install” for more
information.
8. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
-Prime”formoreinformation.
i02295929
Fuel Injection Pump - Remove
Removal Procedure
Table 3
Required Tools
Tool Part
Number Part Name Qty
A21825576 Crankshaft Turning Tool 1
27610289 Crankshaft Turning Tool 1
A
27610290 Gear 1
B27610212 Camshaft Timing Pin 1
C27610286 Crankshaft Timing Pin 1
D-Cap 2
Start By:
a. If necessary, remove the fuel filter base. Refer to
Disassembly and Assembly Manual, “Fuel Filter
Base - Remove and Install”.
b. If necessary, remove the fuel priming pump. Refer
to Disassembly and Assembly Manual, “Fuel
PrimingPump-Remove”.
c. Remove the front cover. Refer to Disassembly
and Assembly Manual, “Front Cover - Remove
and Install”.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.
1. Isolate the fuel supply.
2. Isolate the electrical supply.
3. Use Tooling (A) in order to rotate the crankshaft
so that number one piston is at top dead center
on the compression stroke. Refer to Testing and
Adjusting Manual, “Finding Top Centre Position for
No.1 Piston”.
4. Use Tooling (B) in order to lock the camshaft in
the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, “Gear Group (Front)
- Remove” for the correct procedure.
5. Remove the backlash from the fuel pump gear.
Lock the fuel injection pump in the correct
position and remove the fuel pump gear. Refer to
Disassembly and Assembly, “Fuel Pump Gear -
Remove and Install” for the correct procedure.

SENR9983 17
Disassembly and Assembly Section
g01173307
Illustration 23
Typical example
g01173310
Illustration 24
Typical example
6. Place a suitable container below the fuel injection
pump (1) in order to catch any fuel that might be
spilled.
Note: Clean up any spillage of fuel immediately.
7. Disconnect the plastic tube assembly (2) from the
fuel injection pump (1).
8. Disconnect the engine wiring harness (7) from the
solenoid (3) of the fuel injection pump. Disconnect
the engine wiring harness (7) from the position
sensor (4) for the fuel injection pump.
Note: The engine wiring harness should be
positioned in order to avoid an obstruction to the fuel
injection pump.
9. Remove the plastic tube assembly (11) from the
fuel transfer pump (8).
10. Disconnect the plastic tube assembly (10) from
the outlet of the fuel transfer pump (8).
11. Disconnect the plastic tube assembly (5) from the
fuel injection pump (1).
12. Remove the tube assembly (12) for the fuel return
from the fuel transfer pump and the cylinder head.
Note: Disconnect the tube assembly at the fuel
transfer pump first in order to drain the fuel from the
cylinder head.
13. Remove the tube assembly (9) for the engine oil
supply to the fuel injection pump (1).
14. Plug or cap all open ports and tube assemblies
immediately with new plugs or caps.
15. Remove the fuel injection line (6) that connects
the fuel injection pump to the fuel manifold. Refer
to Disassembly and Assembly Manual, “Fuel
Injection Lines - Remove”. Use Tooling (D) in
order to plug the open ports in the fuel injection
pump and in the fuel manifold. Discard the fuel
injectionline.

18 SENR9983
Disassembly and Assembly Section
g01208416
Illustration 25
16. Remove the two setscrews (15). Remove the two
setscrews (14) and remove the support bracket
(13) from the fuel injection pump (1).
g01173314
Illustration 26
Typical example
17. Remove the three setscrews (17) and sealing
washers (18). Discard the sealing washers.
Note: The fuel injection pump should be supported
by hand as the setscrews are removed.
18. Carefully remove the fuel injection pump (1) from
the front housing (19). Ensure that the bore (20)
in the front housing is not damaged as the fuel
injection pump is removed.
19. Remove the O-ring seal (21) from the fuel
injection pump (1). Discard the O-ring seal.
20. If necessary, remove the position sensor (4) from
the fuel injection pump (1). Refer to Disassembly
and Assembly Manual, “Position Sensor (Fuel
Injection Pump) - Remove and Install”.
21. If necessary, remove the fuel transfer pump
(8) from the fuel injection pump (1). Refer to
Disassembly and Assembly Manual, “Fuel
Transfer Pump - Remove”.
i02295933
Fuel InjectionPump-Install
Installation Procedure
Table 4
Required Tools
Tool
Part
Number Part Description Qty
A21825576 Crankshaft Turning Tool 1
27610289 Crankshaft Turning Tool 1
A27610290 Gear 1
B27610212 Camshaft Timing Pin 1
C27610286 Crankshaft Timing Pin 1
E27610302 Fuel Injection Pump
Timing Tool 1
F21820221 POWERPART
Rubber Grease -
Note: EitherTooling(A)canbeused.UsetheTooling
that is most suitable.
NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorised personnel that have the correct train-
ing.
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information.
Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
information on the standards of cleanliness that
must be observed during ALL work on the fuel
system.

SENR9983 19
Disassembly and Assembly Section
g01174932
Illustration 27
1. If the fuel injection pump was previously
disassembled, follow Steps 1.a and 1.b in order to
assemble the fuel injection pump.
a. Install the fuel transfer pump (8) to the fuel
injection pump (1). Refer to Disassembly and
Assembly Manual, “Fuel Transfer Pump -
Install”.
b. Install the position sensor (4) to the fuel
injection pump (1). Refer to Disassembly and
Assembly Manual, “Position Sensor (Fuel
Injection Pump) - Remove and Install”.
Note: A new fuel injection pump assembly includes
the fuel transfer pump and the position sensor.
2. To check the fuel injection pump timing, follow
Steps 2.a and 2.b.
a. Position Tooling (E) onto the shaft (22) of the
fuel injection pump. Align the lever of Tooling
(E) with the key slot (23). Engage the lever into
the key slot.
b. Insert the locking pin of Tooling (E) into the
hole (24) in fuel injection pump.
If the locking pin can be inserted into the hole,
the fuel injection pump timing is correct.
If the locking pin cannot be inserted into the
hole, the fuel injection pump timing is not
correct.
Note: There should be no resistance when the
locking pin is inserted.
3. If the fuel injection pump timing has been lost
follow Steps 3.a through 3.e in order to reset the
fuel injection pump timing.
a. If necessary, loosen the locking screw (25) on
the fuel injection pump. Slide the spacer (26)
into position (X). Tighten the locking screw (25)
toatorqueof9N·m(80lbin).Thiswillprevent
the locking screw from tightening against the
shaft (22).
The fuel injection pump is now unlocked.
b. Position Tooling (E) onto the shaft (22) of the
fuel injection pump. Align the lever of Tooling
(E) with the key slot (23) in the fuel injection
pump. Engage the lever into the key slot.
c. Use the lever of Tooling (E) to rotate the shaft
(22) until the pin of Tooling (E) can be engaged
into the hole (24). Engage the pin of Tooling
(E) into the hole.
d. Loosen the locking screw (25) in the fuel
injection pump. Slide the spacer (26) into
position (Y). Tighten the locking screw (25)
against the shaft of the fuel injection pump to a
torqueof9N·m(80lbin).
The fuel injection pump is now locked.
e. Remove tooling (E).
g01173314
Illustration 28
Typical example
4. Inspect the bore (20) in the front housing (19)
for damage. If the bore is damaged, replace
the front housing. Refer to Disassembly and
Assembly Manual, “Housing (Front) - Remove”
and Disassembly and Assembly Manual, “Housing
(Front) - Install”.

20 SENR9983
Disassembly and Assembly Section
5. Use Tooling (F) to lubricate a new O-ring seal
(21). Install the O-ring seal onto the fuel injection
pump (1).
6. Align the holes in the fuel injection pump (1) with
the holes in the front housing (19). Carefully install
the fuel injection pump to the front housing.
Note: The fuel injection pump should be supported
by hand until the setscrews are installed.
7. Install the three setscrews (17) and three new
sealing washers (18). Tighten the setscrews to a
torque of 25 N·m(18lbft).
8. If necessary, use Tooling (A) in order to rotate the
crankshaft so that number one piston is at top
dead center on the compression stroke. Refer
to Testing and Adjusting Manual, “Finding Top
Centre Position for No.1 Piston”.
9. Use Tooling (B) in order to lock the camshaft in
the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, “Gear Group (Front)
- Remove” for the correct procedure.
10. Install the fuel injection pump gear to the fuel
injection pump. Refer to Disassembly and
Assembly Manual, “Fuel Injection Pump Gear -
Install” and refer to Disassembly and Assembly
Manual, “Gear Group (Front) - Install”.
Note: Ensure that the spacer (26) on the fuel
injection pump is in the unlocked position (X) after the
installation of fuel injection pump gear is completed.
Refer to Illustration 27.
11. Install the front cover. Refer to Disassembly and
Assembly Manual, “Front Cover - Remove and
Install”.
g01208416
Illustration 29
Typical example
12. Position the support bracket (13) onto the fuel
injection pump (1). Install the two setscrews (14)
finger tight.
13. Install the two setscrews (15) finger tight.
14. Tighten the setscrews (15) to a torque of 22 N·m
(16 lb ft). the setscrews (14) to a torque of 22 N·m
(16 lb ft).
Some engines have a single M10 nut and a bolt in
place of the two setscrews (15). Tighten the nut
and bolt to a torque of 44 N·m (32.5 lb ft).
Note: Ensure that the fuel injection pump is not
stressed as the fasteners for the bracket are
tightened.