Perkins Seria 400 C Typ H... MANUAL

SENR9973-01
September 2007
- Disassembly and Assembly

- Operation and Maintenance Manual
- Systems Operation Testing and Adjusting
- Specifications
400C Industrial Engine

HB (Engine)
HD (Engine)
HH (Engine)
HL (Engine)
HM (Engine)
HN (Engine)
HP (Engine)
HR (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 premature failures, product damage, personal injury or
death.
SENR9973-01
Table of Contents
Disassembly and Assembly Section
Fuel Priming Pump - Remove ................................. 4
Fuel Priming Pump - Install ..................................... 4
Fuel Filter Base - Remove ..................................... 5
Fuel Filter Base - Install ......................................... 6
Fuel Injection Lines - Remove and Install .............. 7
Fuel Shutoff Solenoid - Remove and Install .......... 9
Fuel Injection Pump - Remove ............................ 10
Fuel Injection Pump - Install ................................. 11
Fuel Injector - Remove ........................................ 12
Fuel Injector - Install ............................................ 12
Turbocharger - Remove and Install ..................... 13
Exhaust Manifold - Remove and Install ............... 15
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 17
Inlet and Exhaust Valves - Remove and Install .... 19
Engine Oil Line - Remove and Install ................... 21
Engine Oil Cooler - Remove and Install ............... 23
Engine Oil Relief Valve - Remove and Install ....... 24
Engine Oil Pump - Remove .................................. 24
Engine Oil Pump - Install ...................................... 26
Water Pump - Remove ......................................... 28
Water Pump - Install ............................................. 30
Water Temperature Regulator Housing - Remove and
Install .................................................................. 31
Water Temperature Regulator - Remove and Install
............................................................................. 32
Flywheel - Remove ............................................... 35
Flywheel - Install ................................................... 36
Crankshaft Rear Seal - Remove ........................... 37
Crankshaft Rear Seal - Install ............................... 37
Flywheel Housing - Remove and Install .............. 39
Crankshaft Pulley - Remove and Install ............... 42
Crankshaft Front Seal - Remove .......................... 43
Crankshaft Front Seal - Install .............................. 43
Housing (Front) - Remove .................................... 44
Housing (Front) - Disassemble ............................. 45
Housing (Front) - Assemble .................................. 47
Housing (Front) - Install ........................................ 50
Crankcase Breather - Remove and Install ........... 51
Valve Mechanism Cover - Remove and Install ..... 54
Rocker Shaft and Pushrod - Remove ................... 55
Rocker Shaft - Disassemble ................................ 56
Rocker Shaft - Assemble ..................................... 57
Rocker Shaft and Pushrod - Install ....................... 59
Cylinder Head - Remove ...................................... 60
Cylinder Head - Install .......................................... 61
Lifter Group - Remove and Install ......................... 63
Camshaft - Remove .............................................. 64
Camshaft - Disassemble ....................................... 65
Camshaft - Assemble ........................................... 66
Camshaft - Install .................................................. 66
Engine Oil Pan - Remove and Install ................... 67
Pistons and Connecting Rods - Remove .............. 68
Pistons and Connecting Rods - Disassemble ....... 69
Pistons and Connecting Rods - Assemble ........... 71
Pistons and Connecting Rods - Install .................. 73
Connecting Rod Bearings - Remove .................... 74
3
Table of Contents
Connecting Rod Bearings - Install ........................ 75

Crankshaft Main Bearings - Remove .................... 76
Crankshaft Main Bearings - Install ........................ 77
Crankshaft - Remove ............................................ 78
Crankshaft - Install ................................................ 80
Bearing Clearance - Check ................................... 81
Coolant Temperature Switch - Remove and
Install ................................................................... 82
Engine Oil Pressure Switch - Remove and Install
............................................................................. 84
Glow Plugs - Remove and Install ......................... 86
V-Belts - Remove and Install ................................ 86
Fan - Remove and Install ..................................... 87
Alternator - Remove and Install ........................... 91
Electric Starting Motor - Remove and Install ..... 101
Index Section
Index ................................................................... 103
4
SENR9973-01
Disassembly and Assembly

Section
i02186288
2. Install suitable plugs into the fuel lines in order to

prevent contamination.
3. Remove the two setscrews (4) that fasten the fuel
priming pump (1) to the cylinder block.
Fuel Priming Pump - Remove
Note: The fuel priming pump can be oriented in two

positions. Before removing the fuel priming pump (1)
from the cylinder block, note the orientation of the
flange (2) of the fuel priming pump (1) for assembly.
Removal Procedure
4. Remove the fuel priming pump (1) and the O-ring

(3). Discard the O-ring.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: In order to remove the fuel priming pump

from the engine, it may be necessary to rotate the
crankshaft until the operating plunger of the fuel
priming pump is not under pressure.
i02186279
Fuel Priming Pump - Install

Installation Procedure
NOTICE
component life.
NOTICE
mandates.
Illustration 1
g00824616
Typical example
1. Loosen the hose clamps and remove the two fuel

lines from the fuel priming pump (1). Note the
positions of the fuel inlet and the fuel outlet for
installation.
SENR9973-01
5
i02186242
Fuel Filter Base - Remove

Removal Procedure
NOTICE
component life.
Illustration 2
g01129954
Typical example
1. Clean the mating surfaces of the fuel priming

pump on the cylinder block and clean the flange
(2) of the fuel priming pump.
NOTICE
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
mandates.
Note: Ensure that the camshaft lobe for the fuel

priming pump is at minimum lobe lift before the fuel
priming pump is installed. The fuel priming pump
can be oriented in two positions. Ensure that the fuel
priming 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 priming
pump (1) with clean engine oil.
4. Install the fuel priming pump (1) to the engine.
Ensure that the operating plunger is positioned
correctly on the camshaft lobe.
5. Install the two setscrews (4) that fasten the fuel
priming pump (1) to the cylinder block. Tighten the
setscrews to a torque of 6 Nm (4.5 lb ft).
6. Loosely install the hose clamps to the fuel lines.
Connect the appropriate fuel lines to the fuel inlet
and the fuel outlet of the fuel priming pump (1).
Tighten the hose clamps.
Note: The fuel inlet for the fuel priming can be
rotated 360 degrees by loosening setscrew (5). The
fuel 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 Nm (22 lb in).
7. Prime the fuel system. Refer to Testing and
Adjusting, Fuel System - Prime for additional
information.
Illustration 3
g01118406
Typical example
1. Disconnect the fuel lines (1) and (2). Inspect the

condition of the rubber olives (not shown) that seal
the fuel lines. If the olives are damaged or worn,
use new parts for replacement.
6
SENR9973-01
Note: Put identification marks on all the fuel lines for

installation purposes. Plug all the fuel lines and all
the ports in the fuel filter base. This helps prevent
fluid loss, and this helps to keep contaminants from
entering the system.
2. Remove the fuel filter element (4). Refer to
Operations and Maintenance Manual, Fuel
System 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 (not
shown).
5. Remove the fuel filter base (3) from the engine.
i02186227
Fuel Filter Base - Install

NOTICE
Illustration 4
g01118406
Typical example

component life.
1. Align the fuel filter base (3) with the mounting

bracket. Install the bolts (8) and nuts (not shown).
Tighten the nuts to a torque of 22 Nm (16.2 lb ft).
Note: Some fuel filters are installed by the OEM and
torques for the mounting fasteners may vary. Check
with the OEM Installation Manual for the correct
torque setting.
2. If necessary, install the fuel filter element (4)
to the fuel filter base (3). Refer to Operations
and 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 Nm (6.6 lb ft).
4. If necessary, install new inner seals (7) to the fuel
filter base (3).
Install new washers (6) onto the plugs (5) and
install the plugs (5) to the fuel filter base (3).
Tighten the plugs (5) to a torque of 22.5 Nm
(16.6 lb ft).
SENR9973-01
7
End By:
a. Remove the air from the fuel system. Refer
to Operations and Maintenance Manual, Fuel
System - Prime.
i02801636
Fuel Injection Lines - Remove

and Install
Removal Procedure
NOTICE
component life.
Illustration 5
g00818680
404C-22 and 404C-22T engines
NOTICE
mandates.
NOTICE
Do not let the tops of fuel injectors turn when the fuel
line 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) that
comes out of the nozzle will not be correct.
Note: The removal procedure is similar for the two
cylinder, the three cylinder and the four cylinder
engines. The illustrations show the 404C-22 and
404C-22T engines.
1. Disconnect the union nuts (1) for the fuel injection

lines (2) from the fuel injectors.
2. Disconnect the union nuts (1) for the fuel injection
lines (2) from the fuel injection pump.
3. Remove the fuel injection lines (2) from the engine
as a unit.
Note: Place identification marks on all tube
assemblies for installation. Plug all tube assemblies
in order to prevent contamination.
4. Install suitable plastic plugs to the outlet
connections of the fuel injection pump.
5. The 403C-15, 403C-17, 404C-22 and 404C-22T
engines have a rigid fuel return line.
For engines with a rigid fuel return line, remove
the 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-15
engines have a flexible fuel return hose.
For engines with a flexible fuel return hose,
disconnect the union nut from the banjo piece.
8
SENR9973-01
Note: The installation procedure is similar for the

two cylinder, the three cylinder and the four cylinder
engines. The illustrations show the 404C-22 and
404C-22T engines.
Illustration 6
g00824793
6. Remove the nut (5) from the fuel injectors (7).

7. Remove the fuel return line (3) from the engine
and remove washers (6) from the fuel injectors
(7). Discard the washers.
8. Install suitable plastic plugs to the fuel injectors.
NOTICE
component life.
Illustration 7
g00824793
1. Remove the plastic plugs from the fuel injectors

(7). Install new washers (6) to the fuel injectors
(7) and install the fuel return line (3) to the fuel
injectors.
Note: The washers (6) have two small holes.
2. Install the nuts (5) to the fuel injectors (7).
3. The 403C-15, 403C-17, 404C-22 and 404C-22T
engines have a rigid fuel return line.
NOTICE
Do not let the tops of fuel injectors turn when the fuel
line nuts are loosened or tightened.
For engines with a rigid fuel return line, install new

washers (8) to the fuel return line (3) and install the
banjo bolt (4) to the fuel injection pump. Tighten
the banjo bolt (4) to a torque of 7 Nm (5.2 lb ft).
The nozzles will be damaged if the top of the injector

turns in the body.
The 402C-05, 403C-07, 403C-11 and 404C-15

engines have a flexible fuel return hose.
The engine will be damaged if a defective fuel injector

is used because the shape of fuel (spray pattern) that
comes out of the nozzle will not be correct.
For engines with a flexible fuel return hose,

connect the fuel return hose to the banjo piece
and tighten the union nut.
4. Tighten the nuts (5) to a torque of 27 Nm (20 lb ft).
SENR9973-01
9
i02207974
Fuel Shutoff Solenoid Remove and Install

Removal Procedure
NOTICE
component life.
Illustration 8
g00818680
5. Remove the plastic plugs from the fuel injection

lines (2) and remove the plastic plugs from the
outlet connections of the fuel injection pump.
Install the fuel injection lines to the engine as a
unit.
NOTICE
mandates.
6. Connect the fuel injection lines (2) to the fuel

injection pump.
7. Connect the fuel injection lines (2) to the fuel
injectors (7).
8. For the 402C-05 and 403C-07 engines, tighten
the union nuts (1) to a torque of 20 Nm (15 lb ft).
For the 403C-11, 403C-15,403C-17, 404C-15,
404C-22 and 404C-22T engines, tighten the union
nuts (1) to a torque of 23 Nm (17 lb ft).
9. Prime the fuel system. Refer to Testing and
Adjusting, Fuel System - Prime for more
information.
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.
Illustration 9
g00824952
1. Disconnect electrical connections (3) to the fuel

shutoff 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).
NOTICE
component life.
10
SENR9973-01
NOTICE
mandates.
Illustration 10
g00824952

engines. The illustrations show the four cylinder
engine.
1. Check the condition of O-ring (2). If the O-ring is

worn 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 fuel
shutoff solenoid to a torque of 17.5 Nm (12.9 lb ft).
3. Reconnect electrical connection (3) to fuel shutoff
solenoid (1) before you operate the engine.
i02797470
Fuel Injection Pump - Remove

Illustration 11
g00825132
Typical example
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
Disassembly and Assembly, Fuel Injection Lines
- Remove and Install.
b. Remove the fuel shutoff solenoid. Refer to
Disassembly and Assembly, Fuel Shutoff
Solenoid - Remove and Install.
NOTICE
Illustration 12

component life.
g00825137
Typical example
1. Remove the setscrews (4) and the nuts (2) that

fasten the fuel injection pump to the cylinder block.
Note: If the fuel rack control (5) has not been moved
away from the recess of the stop solenoid, damage
may occur.
SENR9973-01
11
2. Carefully raise the fuel injection pump (1) from

the cylinder block and remove the clip (7) that
connects the link (6) to the fuel rack control (5).
3. Remove the fuel injection pump (1) from the
cylinder block.
4. Remove the shims (3) from the mounting face of
the cylinder block.
Note: Record the thickness of each shim and the
number of shims for reassembly. The fuel injection
timing is determined by the thickness of the shim
pack that is between the fuel injection pump and
the mounting face on the cylinder block. For more
information on the fuel injection pump, refer to
Specifications, Fuel Injection Pump.
i02801637
Fuel Injection Pump - Install
Illustration 13
g00825132
Typical example
2. Install the correct thickness and the correct

number of shims (3) on the mounting face of
the cylinder block. Refer to Specifications, Fuel
Injection Pump.
NOTICE
component life.
NOTICE
mandates.
engine.
1. Clean the mounting face of the fuel injection pump
on the cylinder block. Clean the mating surface of
the fuel injection pump.
Illustration 14
g00825137
Typical example
3. Position the fuel injection pump (1) close to the

mounting face of the cylinder block, and connect
the link (6) and the fuel rack control (5) with the
clip (7).
4. Put the fuel injection pump (1) in position on the
mounting 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-15
engines, tighten the setscrews (4) and the nuts (2)
to a torque of 6 Nm (53 lb in).
For 403C-15, 403C-17, 404C-22 engines and
404C-22T engines, tighten the setscrews (4) and
the nuts (2) to a torque of 15 Nm (11 lb ft).
12
SENR9973-01
End By:
a. Install the fuel shutoff solenoid. Refer to
Disassembly and Assembly, Fuel Shutoff
Solenoid - Remove and Install.
b. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection Lines - Remove
and Install.
i02801638
Fuel Injector - Remove

Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to
NOTICE
component life.
NOTICE
mandates.
Illustration 15
g01124706
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 seat
washers. 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. Cap all openings or plug all openings immediately
after disassembly.
i02801639
Fuel Injector - Install

NOTICE
component life.
SENR9973-01
13
i02186260
Turbocharger - Remove and

Install
Removal procedure
NOTICE
component life.
Illustration 16
g01113718
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.
NOTICE
mandates.
2. Install new seat washers (3) into the injector bore

in the cylinder head.
Note: 402C-05 and 403C-07 engines have two seat
washers. 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 1861117 POWERPART Universal
Jointing Compound (2) to the first two threads of
the injector that engage into the cylinder head.
The bead of Universal Jointing Compound should
have a diameter of 2 mm (0.08 inch) and a length
of 6 mm (0.25 inch).
Note: Ensure that the universal jointing compound
does not cover the surface of the fuel injector body
below the threads.
4. Install the fuel injector (1) into the cylinder head.
Use a deep socket to tighten the fuel injector to a
torque of 64 Nm (47 lb ft).
Note: If a new fuel injector has been installed, do not
make any adjustments to the engine controls. Refer
to Testing and Adjusting, Engine Speed - Check
for more information.
Illustration 17
End By:
a. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection Lines - Remove
and Install.
g01114005
1. Clean the outer surfaces of the turbocharger (1).

2. Loosen the hose clamps (4). Remove the air inlet
hose (5).
14
SENR9973-01
9. Remove the nuts (19) and the washers (18).

Remove the turbocharger (1) from the exhaust
manifold. Remove the turbocharger gasket (23)
from the exhaust manifold. Discard the gasket.
If necessary, remove the studs (17) from the
exhaust manifold.
Note: Do not use the actuator rod of the wastegate
to lift the turbocharger.
10. Inspect the turbocharger for damage. If the
turbocharger is damaged use a new part for
replacement. Refer to Testing and Adjusting,
Wastegate - Test.
11. Install suitable plastic plugs into the oil supply
and into the oil drain ports of the turbocharger (1).
Install suitable plastic covers to the inlet and to the
outlet of the turbocharger. Install suitable plastic
plugs to the oil supply tube assembly (8) and to
the oil drain tube assembly (11).
Illustration 18
g01114003
3. Remove the exhaust pipe (not shown) from the

exhaust elbow (21). Refer to the OEM provided
information for the correct procedure in order to
remove the exhaust pipe.
4. Remove the setscrews (15) and remove the
support bracket for the turbocharger (16). Note
the position of the support bracket for installation.
5. Remove the setscrews (22). Remove the exhaust
elbow (21) from the turbocharger (1). Remove
the gasket for the exhaust elbow (20) from the
turbocharger. Discard the gasket.
Installation procedure
NOTICE
component life.
1. Remove all of the plastic plugs from all of the ports
of the turbocharger (1). Clean the mating surfaces
of the exhaust manifold and the turbocharger.
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 supply
tube 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 the
cylinder block. Remove the O-ring (9). Discard
the O-ring.
8. Remove the setscrews (13). Remove the oil
drain tube assembly (11) from the turbocharger.
Remove the joint (14) and discard the joint. If
necessary, remove the setscrews (12) and remove
the oil drain tube assembly (11) from the cylinder
block. Remove the joint (10). Discard the joint.
Illustration 19
g01114003
2. Ensure that all of the turbocharger inlet and outlet

ports are clean and free from restrictions. The
turbocharger shaft must rotate freely.
SENR9973-01
15
3. If the studs (17) were previously removed, install

the studs into the exhaust manifold. Install a new
gasket (23) over the studs (17).
Note: Do not use any sealant on the gasket (23).
Note: Do not use the actuator rod of the wastegate
to lift the turbocharger (1).
4. Position the turbocharger (1) onto the exhaust
manifold.
5. Install the washers (18) and install the nuts (19).
Tighten the nuts to a torque of 25 Nm (18 lb ft).
6. Lubricate the bearing housing of the turbocharger
(1) with clean engine oil. Apply the lubricant
through the oil supply port (24).
10. Position the new washers (2) and the oil supply
tube assembly (8) onto the turbocharger (1).
Install the banjo bolt (3). Tighten the banjo bolt to
a torque of 18 Nm (13 lb ft).
11. If necessary, install a new O-ring (9) and the oil
supply tube assembly (8) to the cylinder block.
Install the setscrews (7). Tighten the setscrews to
a torque of 10 Nm (7 lb ft).
12. If necessary, install the spacer (not shown) and
install the setscrews (not shown) to the tube clips
(6). Torque the setscrews to 10 Nm (7 lb ft).
Note: Ensure that the oil supply tube assembly (8)
does not come into contact with any other component
when the assembly is installed onto the engine.
13. Clean the mating surfaces of the exhaust elbow
(21). Position a new gasket (20) and the exhaust
elbow (21) on the turbocharger (1). Install the
setscrews (22). Tighten the setscrews to a torque
of 32 Nm (24 lb ft).
14. Install the set screws (15) and install the support
bracket for the turbocharger (16). Tighten the
setscrews to a torque of 25 Nm (18 lb ft).
15. Ensure that the inlet hose (5) is clean and free
from defects or restrictions. Loosely install the
hose clamps (4) to the air inlet hose (5). Install
the air inlet hose to the connection of the inlet
manifold and to the inlet of the turbocharger.
Tighten the hose clamps.
Note: Do not use oil or grease in order to install the
air inlet hose. In order to install a new air inlet hose,
lubricate the connection of the inlet manifold and
lubricate the inlet of the turbocharger with a solution
of water and 5% soap.
16. Position the exhaust pipe onto the exhaust elbow
(21). Refer to the OEM information for the correct
procedure in order to install the exhaust pipe.
Illustration 20
i02801640
g01114005
7. Clean the oil supply tube assembly (8) and the oil
drain tube assembly (11). Inspect the oil supply
tube assembly and the oil drain tube assembly. If
necessary, replace the tube assemblies.
8. Position a new joint (14) and the oil drain tube
assembly (11) onto the bottom of the turbocharger.
Install the setscrews (13). Tighten the setscrews
to a torque of 10 Nm (7 lb ft).
9. If necessary, position a new joint (10) and the oil
drain tube assembly (11) onto the cylinder block.
Install the setscrews (12). Tighten the setscrews
Exhaust Manifold - Remove

and Install
Removal Procedure
NOTICE
component life.
16
SENR9973-01
Note: The two cylinder, the three cylinder and the four
cylinder engines have different exhaust manifolds.
The removal procedure is similar for all models.
Illustration 22
g00825291
Typical example
Illustration 21
g00825291
Typical example
1. Loosen the nuts (5) and the setscrews (6).

Note: In order to prevent distortion of the exhaust
manifold, loosen the outer fasteners first.
2. Remove the nuts (5) and the setscrews (6).
Note: Identify setscrews of different lengths so
that the setscrews can be reinstalled in the correct
positions.
1. If necessary, install the exhaust manifold studs

(2) to cylinder head (1).
2. Install a new exhaust manifold gasket (3) to the
cylinder head (1).
Note: Do not use any sealant on the exhaust
manifold gasket.
3. Put the exhaust manifold (4) in position on the
cylinder head (1).
4. Install the nuts (5) and the setscrews (6).
3. Remove the exhaust manifold (4) from the cylinder

head (1).
Note: Ensure that setscrews with different lengths

are installed in the correct holes.
4. Remove the gasket (3) from the cylinder head.
5. For 402C-05, 403C-07, 403C-11 and 404C-15

engines, tighten the nuts (5) and the setscrews (6)
to a torque of 10 Nm (89 lb in).
5. Remove any remaining gasket material and

carbon from the cylinder head and the exhaust
manifold. Be careful not to damage the mating
surface on the cylinder head or the mating surface
on the exhaust manifold.
6. If necessary, remove the exhaust manifold studs
(2) from the cylinder head (1).
NOTICE
component life.
cylinder engines have different exhaust manifolds.
The installation procedure is similar for all models.
For 403C-15, 403C-17, 404C-22 and 404C-22T

engines, tighten the nuts (5) and the setscrews (6)
Note: On three cylinder engines, tighten the two inner
setscrews first. On four cylinder engines, tighten the
four inner setscrews first. Then tighten the two outer
setscrews and the two nuts.
SENR9973-01
17
i02187986
Inlet and Exhaust Valve

Springs - Remove and Install
NOTICE
Install suitable plugs to the inlet ports of the cylinder
head in order to prevent the entry of loose parts into
the engine.
Removal Procedure
Table 1
Required Tools
Part Number
Part Description
Qty
21825666
Valve Spring Compressor
27610235
Adapter
Start By:
a. Remove the rocker shaft assembly. Refer to
Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
NOTICE
component life.
Note: Before you begin the removal of the valve
springs, 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 adopted
in order to remove the valve springs when the
cylinder head is still installed onto the cylinder block.
Refer to Disassembly and Assembly, Inlet and
Exhaust Valves - Remove and Install for the correct
procedure that should be used to remove the valve
springs from a cylinder head that has been removed
from the cylinder block.
Note: Ensure that the appropriate piston is at top
dead 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 by

parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
Illustration 23
g01015085
Typical example
1. Use the following procedure in order to find the

top 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 to
compress the appropriate valve spring (5).
b. Compress the valve spring (5) sufficiently in
order to open the valve only. Do not compress
the valve spring so that the valve keepers (3)
could be removed from the recess in the valve
stem or so that the valve stem seal (not shown)
could be damaged.
c. Slowly turn the crankshaft until the piston
touches the valve.
d. Continue to turn the crankshaft and release the
pressure on the valve spring compressor (1)
until the piston is at the top center position.
NOTICE
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur.
Note: If you are replacing all of the valve springs,
on four cylinder engines only, the procedure can
be done on two cylinders at the same time. The
procedure can be done on cylinder 1 and cylinder 4,
or on cylinder 2 and cylinder 3. Remember that the
crankshaft must not be turned while the valve springs
are removed. Ensure that all of the valve springs are
installed before changing from one pair of cylinders
to the other pair of cylinders.
18
SENR9973-01
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
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 remove
the valve spring (5).
Illustration 24
Table 2
Typical example
Required Tools
Part Number
Part Description
g01015085
Qty
21825666
1. Place the new valve springs (5) into position on

the cylinder head.
27610235
Adapter
2. Install the valve spring retainer (4).
NOTICE
component life.
Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.
NOTICE
Install suitable plugs to the inlet ports of the cylinder
head in order to prevent the entry of loose parts into
the engine.
3. Install the valve spring compressor (1) and the

adapter (2) in position on the cylinder head in
order to compress the appropriate valve spring
(5). Compress the valve spring (5).
NOTICE
4. Install two valve keepers (3) in order to lock the
valve springs in position.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
5. Carefully release the pressure on the valve
spring compressor (1). Remove the valve spring
compressor. Ensure that all of the valves are
secured in place by a valve spring and valve
keepers. Rotate the crankshaft through about
45 degrees in order to clear the piston from the
valve. Lightly strike the top of the valve with a soft
hammer 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 can
be done on two cylinders at the same time. The
procedure can be done on cylinder 1 and cylinder 4,
or on cylinder 2 and cylinder 3.
SENR9973-01
19
End By:
a. Install the rocker shaft assembly. Refer to
Pushrod - Install.
i02187989
Inlet and Exhaust Valves Remove and Install

Removal Procedure
Table 3
Required Tools
Part Number
Part Description
Qty
21825666
27610235
Adapter
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
NOTICE
component life.
Note: The removal procedure is identical for the
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 are
removed. Refer to Specifications, Cylinder Head
Valves 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 surface
with the valve springs facing upward.
Note: Ensure that the machined face of the cylinder
head is kept on a clean, soft surface in order to
prevent damage to the machined surface.
Illustration 25
g01015085
Typical example
4. Install the 21825666 Valve Spring Compressor

(1) and the 27610235 Adapter (2) in position
on the cylinder head in order to compress the
appropriate valve spring (5).
NOTICE
5. Apply pressure to the valve spring compressor (1).
Remove the valve keepers (3).
6. Slowly release the pressure on the valve spring
compressor (1).
20
SENR9973-01
1. Clean all parts. Ensure that all ports, all coolant

passages and all lubrication passages are free
from 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 Head
Valves and refer to Testing and Adjusting, Valve
Depth - Inspect for further information.
3. Inspect all of the valve guides for wear and for
damage. Refer to Specifications, Cylinder Head
Valves and refer to Testing and Adjusting , Valve
Guide - Inspect for further information.
g01113619
Illustration 26
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 the
adapter (2).
11. Remove the valve stem seals (6).
12. Carefully turn over the cylinder head.
Illustration 27
13. Remove the valves (7).
Typical example
4. Lubricate the stems of all valves (7) with clean

engine oil. Install the valves (7) in the appropriate
positions.
Table 4
Required Tools
Part Number
Part Description
g01113619
Qty
21825666
27610235
Adapter
NOTICE
component life.
Note: The installation procedure is identical for the
engine.
5. Carefully turn over the cylinder head and ensure

that all of the valves remain in place.
6. Use a suitable tool to install the new valve stem
seals (6) onto each of the valve guides.
Note: The outer face of the valve guides must be
clean and dry before installing the valve stem seals
(6). The inlet valve stem and the exhaust valve stem
use seals that are different parts.
7. Inspect the valve springs (5) for wear and for the
correct installed length. Refer to Specifications,
Cylinder Head Valves for further information.
8. Install the valve spring (5) onto the cylinder head.
SENR9973-01
21
14. Remove the valve spring compressor (1) and the

adapter (2) from the cylinder head.
9. Install the valve spring retainer (4).

15. Place the cylinder head on a suitable support.

Ensure that the heads of the valves are not
obstructed. Gently strike the top of the valves with
a soft hammer in order to ensure that the valve
keepers (3) are properly installed.
16. Turn over the cylinder head and check the depth
of 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 Disassembly
and Assembly, Cylinder Head - Install.
i02801641
Engine Oil Line - Remove and

Install
Illustration 28
g01015303
Removal Procedure
Typical example
NOTICE
10. Install the 21825666 Valve Spring Compressor
(1) and the 27610235 adapter (2) in position
on the cylinder head in order to compress the
appropriate valve spring (5).
NOTICE
11. Apply pressure to the valve spring compressor
(1). Install the valve keepers (3).
The valve keepers can be thrown from the valve

when the valve spring compressor is released. Ensure that the valve keepers are properly installed
on the valve stem. To help prevent personal injury,
keep away from the front of the valve keepers and
valve springs during the installation of the valves.
12. Carefully release the pressure on the valve spring
compressor (1).
13. Repeat steps 8 to 12 for all of the valves.
Illustration 29
g01117696
Typical example
1. Loosen the nut (2) that attaches the oil line (1) to
22
SENR9973-01
2. Remove the banjo bolt (3) and remove the

washers (4) from the cylinder block. Discard the
washers (4).
Illustration 30
g01117697
Typical example
3. Remove the banjo bolt (3) and remove the

washers (4) from the cylinder head. Discard the
washers (4).
4. Remove the oil line (1) from the engine.
Illustration 31
g01117696
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 the
cylinder block.
Illustration 32
Typical example
g01117697
SENR9973-01
23
3. Position the banjo bolt (3) and the new washers

(4) to the oil line (1). Install the oil line to the
cylinder head.
4. Install the nut (2) that attaches the oil line (1) to
For the 402C-05, 403C-07, 403C-11 and 404C-15
engines, tighten the nut (2) to a torque of 6 Nm
(4.4 lb ft).
For the 403C-15, 403C-17, 404C-22 and
404C-22T engines, tighten the nut (2) to a torque
5. Tighten the banjo bolts (3) to 11.5 Nm (8.5 lb ft).
i02186236
Engine Oil Cooler - Remove

and Install
Illustration 33
Removal Procedure
2. By using a suitable strap wrench, remove the

oil filter element (5) from the oil cooler body (3).
Discard the oil filter element in a suitable manner.
NOTICE
component life.
NOTICE
mandates.
1. Drain the coolant from the cooling system into
a suitable container. Drain the engine oil into a
suitable container. Refer to the Operation and
Maintenance Manual for the procedure on draining
the coolant and the engine oil.
g01113679
3. Remove the hose clamps (2) and the hoses (1)

from the coolant inlet and the coolant outlet on
the oil cooler body (3). Note the positions of the
coolant 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.
NOTICE
component life.
1. Clean the mating surfaces of the oil cooler base
on 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 Nm (25 lb ft).
24
SENR9973-01
4. Install the appropriate hoses (1) to the coolant

inlet 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) with
clean engine oil. Install the new oil filter element to
the oil cooler body (4). Tighten the oil filter element
by hand. Do not use a strap wrench to tighten the
oil filter element.
6. Fill the cooling system with coolant. Fill the
lubrication system with engine oil. Refer to the
Operation and Maintenance Manual, Refill
Capacities for the cooling system capacity and
for the lubrication system capacity of the engine.
1. Remove the engine oil relief valve (2) from the

cylinder block.
2. Remove the O-ring (1) from the engine oil relief
valve. Discard the O-ring.
NOTICE
component life.
i02182334
Engine Oil Relief Valve Remove and Install

Removal Procedure
NOTICE
component life.
NOTICE
mandates.
Illustration 35
g00820218
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 a
i02182152
Engine Oil Pump - Remove

Removal Procedure
Start By:
a. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove.
NOTICE
Illustration 34
g00820218

component life.
SENR9973-01
25
3. Remove the idler gear (3) from the idler hub (1).
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
NOTICE
mandates.
Engine Oil Pump
Illustration 36
g00825411
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)
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 can
be removed by using the following procedure:
a. Remove the engine oil pan. Refer to
Disassembly and Assembly, Engine Oil Pan Remove and Install.
Illustration 37
g00825406
Typical example
b. Remove the setscrews (12) and the oil strainer

(13) from the cylinder block. Inspect the
oil strainer for damage. If the oil strainer is
damaged, 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.
26
SENR9973-01
Idler Hub
NOTICE
component life.
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
Idler Hub
g00831103
Illustration 38
Typical example
1. Remove the crankshaft. Refer to Disassembly and

Assembly, Crankshaft - Remove.
2. Use a hammer and use a suitable drift to remove
idler hub (1) from the cylinder block (2). Align the
drift to the rear face of the hub and drive the hub
from the inside of the cylinder block outward.
i02801642
Illustration 39
Engine Oil Pump - Install
g01297224
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) with
pin of Tooling (A).
Table 5
3. Use a hammer in order to strike the guide plate of

Tooling (A). This will install idler hub (1).
Required Tools
Tool
Part
Number
A(1)
21825624
Alignment Tool
A(2)
21825625
Alignment Tool
A(3)
21825626
Alignment Tool
Multipurpose Grease
(1)
(2)
(3)
Part Description
402C-05 and 403C-07 engines

403C-11 and 404C-15 engines
403C-15, 403C-17, 404C-22 and 404C-22T engines
Qty
4. Remove Tooling (A).
SENR9973-01
27
Engine Oil Pump

Personal injury can result from the release of the
spring force.
The drive shaft, the piston, and the drive gear are
under spring force.
Use a press to slowly release the spring force before the components are removed.
4. Install the following items to idler hub (1):
Oil pump cover (5)

Illustration 40
g00825411
Shim (6)
Spring (7)
Collar (8)
Refer to Illustration 40.
5. Install retaining ring (9) on idler hub (1).
Illustration 41
g01297225
Illustration 42
g01298012
Checking end play by using a feeler gauge
Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equipment.
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 the
respective timing marks on gears (14) and (15).
Install idler gear (3) onto idler hub (1).
3. Install inner rotor (4) to idler gear (3).
6. Use a feeler gauge in order to measure the end

play of engine oil pump. Refer to Specifications,
Engine Oil Pump.
7. If the oil strainer was removed, use the following
procedure for installation:
28
SENR9973-01
NOTICE
mandates.
Illustration 43
g01037619
a. Install a new O-ring seal (10) on oil tube

assembly (11).
b. Install oil tube assembly (11) in the cylinder
block.
1. Drain the coolant from the cooling system into a

suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, Refill
Capacities for the approximate capacity of the
cooling system.
2. Loosen the clamps and remove the hose from the
water pump inlet (not shown).
c. Install oil strainer (13) to the cylinder block and

tighten bolts (12) to a torque of 11 Nm (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 Disassembly
and Assembly, Engine Oil Pan - Remove and
Install.
i02801654
Water Pump - Remove
Illustration 44
g01124100
Typical example
3. Remove the fasteners (2) and the alternator

bracket (1) from the water pump (3).
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.
NOTICE
component life.
SENR9973-01
29
NOTICE
mandates.
cooling system.
2. Loosen the clamps and remove the hose from the
water pump inlet (not shown).
Illustration 45
g01124257
Typical example
4. Loosen the clamps (2) and remove the bypass

hose (3) from the water pump (6).
5. Remove the setscrews, the washers (4) and the
nut (5).
6. If necessary, gently tap the water pump (6) with a
soft 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).
Illustration 46
g01124100
typical example
Removal Procedure (402C-05 and

403C-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.
NOTICE
component life.
3. Remove the fasteners (2) and the alternator

bracket (1) from the water pump (3).
30
Illustration 47
SENR9973-01
g01124046
Illustration 48
g01124257
Typical example
Typical example
4. Loosen the clamps (3) and remove the bypass

hose (4) from the water pump (7).
2. Install a new gasket (1) in position on the engine.
5. Remove the setscrews, the washers (5) and the

nut (6).
3. Place the water pump (6) in position on the engine

and install the setscrews, the washers (4) and the
nut (5). Tighten setscrews, the washers (4) and
the nut (5) to a torque of 10 Nm (7.4 lb ft).
6. If necessary, gently tap the water pump (7) with a

soft 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
component life.
1. Remove all debris and gasket material from
the mating surfaces of the water pump and the
cylinder block.
Illustration 49
g01124637
Typical example
4. Place the alternator bracket (1) into position on

water pump (6). Install the fasteners (2) on the
water 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. Install
the hose (3) on the water pump (6) and tighten the
hose clamps (2) to a torque of 2.5 Nm (22.1 lb in).
SENR9973-01
31
End By:
a. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
Manual, Refill Capacities.
b. Install the pulley, the adapter and the fan. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
c. Install the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install.
Installation Procedure (402C-05

and 403C-07 Engines)
Illustration 51
g01124662
Typical example
NOTICE
component life.
1. Remove all debris and gasket material from
the mating surfaces of the water pump and the
cylinder block.
4. Place the alternator bracket (1) into position on

water pump (7). Install the fasteners (2) on the
water 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. Install
the hose (4) on the water pump (7) and tighten the
hose clamps (3) to a torque of 2.5 Nm (22.1 lb in).
End By:
a. Fill the cooling system with coolant to the correct
Manual, Refill Capacities.
b. Install the pulley, the adapter and the fan. Refer to
Disassembly and Assembly, Fan - Remove and
Install.
c. Install the V-Belts. Refer to Disassembly and
i02182980
Water Temperature Regulator

Housing - Remove and Install
Illustration 50
g01124046
Typical example
2. Install new gaskets (8) and (2) and the spacer (1)
in position on the engine.
3. Place the water pump (7) in position on the engine
and install the setscrews, the washers (5) and the
nut (6). Tighten setscrews, the washers (5) and
the nut (6) to a torque of 10 Nm (7.4 lb ft).
Removal Procedure
NOTICE
component life.
32
SENR9973-01
NOTICE
mandates.
to the OEM for the approximate capacity of
the cooling system. Refer to the Operation and
Maintenance Manual, Cooling System Coolant
(DEAC) - Change or Operation and Maintenance
Manual, Cooling System Extended Life Coolant
- Change.
Illustration 53
g01124076
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) that
fasten the water temperature regulator housing
to the cylinder head. Tighten the fasteners to a
torque of 10 Nm (7.4 lb ft).
5. Fill the cooling system with coolant to the correct
level. Refer to the Operation and Maintenance
Manual, Refill Capacities for more information.
i02801658
Illustration 52
g01124076
Typical example
Water Temperature Regulator Remove and Install
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.
NOTICE
component life.
1. Clean the mating surfaces of the cylinder
head. Clean the mating surfaces of the water
temperature regulator housing.

403C-07 engines)
NOTICE
component life.
SENR9973-01
33
NOTICE
6. Inspect the water temperature regulator (2)

for wear or damage. If the water temperature
regulator is worn or damaged, use a new part
for replacement. Refer to Testing and Adjusting,
Water Temperature Regulator - Test for more
information on testing the water temperature
regulator.

mandates.

403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines)

cooling system.
NOTICE
component life.
NOTICE
mandates.
Illustration 54
g01112497
Typical example

cooling system.
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts 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) and
the spring (1) from the cylinder head.
Illustration 55
Typical example
2. Remove the setscrews (1).
g01125880
34
SENR9973-01
3. Remove the outlet connection (2) for the water

temperature regulator.
Note: Identify the orientation of the outlet connection
for installation.
4. Remove the joint (3).
5. Remove the water temperature regulator (4) from
the water temperature regulator housing (5).
6. Inspect the water temperature regulator (4)
for wear or damage. If the water temperature
regulator is worn or damaged, use a new part
for replacement. Refer to Testing and Adjusting,
Water Temperature Regulator - Test for more
information on testing the water temperature
regulator.

and 403C-07 engines)
NOTICE
component life.
1. Remove all debris and gasket material from the
mating surfaces of both the outlet connection
(4) for the water temperature regulator and the
cylinder head.

Illustration 56
g01112497
2. Install the spring (1) and the water temperature

regulator (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 the
outlet connection (4).
6. Tighten the fasteners to a torque of 6 Nm
(53 lb in).

403C-15, 403C-17, 404C-15, 404C-22
and 404C-22T engines)

NOTICE
component life.
1. Remove all debris and all gasket material from the
mating surfaces of both the outlet connection (2)
and the water temperature regulator housing (5).
SENR9973-01
35
NOTICE
component life.
Note: The two cylinder, the three cylinder and the
four cylinder engines have different flywheels. The
removal procedure is similar for all models.
Illustration 57
g01125880
2. Install the water temperature regulator (4) to the

water temperature regulator housing (5). Refer
to specifications, Water Regulator Housing
for 403C-11, 403C-15, 403C-17, 404C-15,
404C-22and 404C-22T Engines for the correct
orientation of the water temperature regulator.
Illustration 58
g01123637
Typical example
3. Install a new joint (3) to the cylinder head.
1. Install a suitable lifting device (1) to the flywheel

(2).
4. Install the outlet connection (2) to the water

temperature regulator housing (5).
2. Remove two setscrews (3) opposite each other

from the flywheel.
Note: Ensure the correct orientation of the outlet

connection.
3. Install two suitable guide studs in the place of the

setscrews that were removed.
5. Install the setscrews (1) to the outlet connection

(2).
4. Remove the remaining setscrews (3) that fasten

the flywheel to the crankshaft.
6. Tighten the setscrews to a torque of 14 Nm

(10 lb ft).
5. Remove the flywheel (2) from the rear of the

crankshaft.

Note: On some three cylinder engines, a roll pin is

located between the crankshaft and the flywheel.
i02183594
Flywheel - Remove
Removal Procedure
Start By:
a. Remove the electric starting motor. Refer to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
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 parts
for replacement.
36
SENR9973-01
Illustration 60
g01124041
Typical example
Illustration 59
g01123614
Typical example
7. To remove the flywheel ring gear (5) from the

flywheel (2), place the flywheel on a suitable
support. Use a suitable hammer (not shown) and
a punch (4) in order to remove the ring gear from
the flywheel.
i02183590
Flywheel - Install
NOTICE
component life.
1. Thoroughly clean the flywheel housing. Inspect

the crankshaft rear seal for leaks. If there are
any oil leaks refer to Disassembly and Assembly,
Crankshaft Rear Seal - Remove.
2. If necessary, perform the following procedure to
install the ring gear (2) to the flywheel (1).
a. Identify the orientation of the new ring gear in
order to install the ring gear correctly onto the
flywheel.
Note: The chamfered side of the gear teeth (3) must
face toward the starting motor when the flywheel is
installed. This will ensure the correct engagement of
the starting motor.
b. Heat the flywheel ring gear (2) in an oven to a
maximum temperature of 150C (302F) 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 onto
the flywheel (1).
Always wear protective gloves when handling

parts that have been heated.
Illustration 61
Typical example
g01124042
SENR9973-01
37

(1).
4. Install two suitable guide studs opposite each
other 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 crankshaft
and that the roll pin is free from damage. Align
the hole in the flywheel with the roll pin in the
crankshaft.
6. Install the setscrews (5) that fasten the flywheel
to the crankshaft.
NOTICE
mandates.
four cylinder engines have different configurations for
the flywheel housing and the backplate. The removal
process is similar for all models.
7. Remove the two guide studs and install the two

remaining 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 Nm (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 to
Disassembly and Assembly, Electric Starting
Motor - Remove and Install.
i02183600
Crankshaft Rear Seal - Remove
Illustration 62
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 the
cylinder block. Discard the used crankshaft oil
seal.
Removal Procedure
Start By:
a. Remove the flywheel housing. Refer to
Disassembly and Assembly, Flywheel Housing
NOTICE
component life.
g00847841
i02801659
Crankshaft Rear Seal - Install

Note: Inspect the crankshaft rear seal and replace
the assembly if there is the slightest sign of damage
to the seal.
Note: The following procedure assumes that the
crankshaft rear seal is a replacement assembly.
38
SENR9973-01
NOTICE
component life.
Illustration 63
g01113706
Typical example
1. Clean the rear face of the cylinder block (1) and

the back plate (6). Inspect the dowels (3) for
damage. If the dowels are damaged, use new
parts for replacement.
2. Ensure that the crankshaft flange (4) is clean, dry
and free from rough metal edges.
3. Remove the packaging from the new crankshaft
rear seal (5). Ensure that the plastic sleeve (not
shown) is squarely installed within the crankshaft
rear seal. The plastic sleeve is included in order
to protect the lip of the seal as the lip is pushed
over the crankshaft flange.
4. Apply clean engine lubricating oil to the crankshaft

flange (4) around the running surface of crankshaft
rear seal.
5. Place the crankshaft rear seal (5) over the
crankshaft flange (4) and engage the plastic
sleeve onto the crankshaft flange.
6. Ensure that the plastic sleeve is engaged onto
the crankshaft flange (4). Push the crankshaft
rear seal (5) evenly and push the crankshaft rear
seal smoothly onto the crankshaft flange until the
crankshaft rear seal is against the cylinder block.
During this process, the plastic sleeve will be
forced out of the crankshaft rear seal. Discard the
plastic sleeve.
SENR9973-01
39
7. Apply a continuous bead of 21826038

POWERPART Silicone Adhesive to the rear face
of the cylinder block around the mating surface of
the crankshaft rear seal and around the rear core
plug 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, tighten
the setscrews to a torque of 15 Nm (11 lb ft).
g00827061
For the 403C-11 and 404C-15 engines, tighten the

Illustration 64
For the 403C-15, 403C-17, 404C-22 and

404C-22T engines, tighten the setscrews to a
3. Remove the setscrews (3) that fasten the flywheel

housing (8) to the cylinder block.
Typical example
End By:
4. Remove the setscrews (5) on each side of

the cylinder block. These setscrews fasten the
flywheel housing (8) to the cylinder block.
a. Install the flywheel housing. Refer to Disassembly

and Assembly Manual, Flywheel Housing Remove and Install.
5. Remove the setscrews (1) that fasten the back

plate (2) to the flywheel housing (8).
b. Install the flywheel. Refer to Disassembly and

Assembly Manual, Flywheel - Install.
6. Remove the nuts (7) and the bolts (not shown)

that fasten the back plate (2) to the flywheel
housing (8).
i02801660
Flywheel Housing - Remove

and Install
Removal Procedure (Engines with
Flywheel Housing and Back plate)
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
component life.
Illustration 65
g01113237
Typical example
1. Support the engine with a suitable lifting device or

support the engine on blocks that are positioned
on a flat level surface.
housing and support the weight of the housing (8).
7. Use the lifting device (9) to remove the flywheel

housing (8) from the back plate.
40
SENR9973-01
Removal Procedure (Engines with

Flywheel Housing)
Start By:
a. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove.
NOTICE
component life.
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 positioned
on a flat level surface.
Illustration 67
g01123555
Typical example

housing and support the weight of the housing (2).
4. Use the lifting device (3) to remove the flywheel

housing (2) from the engine.
Installation Procedure (Engines

with Flywheel Housing and Back
plate)
NOTICE
component life.
Illustration 66
g01123577
Typical example
3. Remove the setscrews (1) that fasten the flywheel

Illustration 68
Typical example
g00827061
SENR9973-01
41
1. Clean the rear face of the back plate (2) and the
faces of the flywheel housing (8). Inspect the
crankshaft rear seal (not shown) for leaks. Inspect
the dowels (6) for damage. If the crankshaft
rear seal or the dowels are damaged, use new
parts for replacement. Refer to Disassembly and
Assembly, Crankshaft Rear Seal - Remove and
Disassembly and Assembly, Crankshaft Rear
Seal - Install.
Installation Procedure (Engines

with Flywheel Housing)
NOTICE
component life.
Illustration 70
g01123556
Typical example
Illustration 69
g01113237
Typical example
2. Use the lifting device (9) to align the flywheel

housing (8) to the dowels (6). Install the flywheel
housing to the back plate.
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 are
damaged, use new parts for replacement. Refer
to Disassembly and Assembly, Crankshaft Rear
Seal - Remove and Disassembly and Assembly,
Crankshaft Rear Seal - Install.
3. Install the nuts (7) and the bolts (not shown) that
fasten 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 the
cylinder block. These setscrews fasten the
flywheel housing (8) to the cylinder block.
6. Remove the lifting device (9) from the flywheel
housing.
8. For 403C-15, 404C-22 and 404C-22T engines,
tighten the fasteners to a torque of 25 Nm
(19 lb ft).
End By:
a. Install the flywheel. Refer to Disassembly and
Assembly, Flywheel - Install.
Illustration 71
g01123555
Typical example
2. Use the lifting device (3) to align the flywheel

housing (2) to the dowels (5). Install the flywheel
housing to the engine.
42
SENR9973-01

housing to the cylinder block.
For 402C-05 and 403C-07 engines, tighten the
4. Remove the lifting device (3) from the flywheel
housing.
g01122953
End By:
Illustration 73
a. Install the flywheel. Refer to Disassembly and

2. Install the 21825619 Puller (6) to the crankshaft

pulley. Use the puller (6) in order to remove the
crankshaft pulley (2) from crankshaft (4).
i02801663
Crankshaft Pulley - Remove

and Install
3. Remove the woodruff key (1) from the crankshaft

(4).
Removal Procedure
Table 6
Required Tools
Part Number
21825619
Description
Qty
Puller
1. Remove the fan drive belt. Refer to Disassembly

and Assembly, V Belts Remove and Install for
more information.
Illustration 74
g00827213
Note: Inspect the following components for damage:

the taper of the crankshaft, the woodruff key, and
the bore of the crankshaft pulley. Replace any
components that are damaged. Ensure that the taper
of the crankshaft and the bore of the crankshaft
pulley are clean and dry before assembly.
1. Install the woodruff key (1) to the crankshaft (4).
2. Install the crankshaft pulley (2) to the crankshaft
(4).
Illustration 72
g00827213
1. Remove the nut (5) and the washer (3) from

crankshaft pulley (2).
3. Install the washer (3) to the crankshaft (4).

4. Lubricate the nut (5) with clean engine oil and
install the nut.
nut (5) to a torque of 93 Nm (69 lb ft).
SENR9973-01
43
For 403C-11 and 404C-15 engines, tighten the nut

(5) to a torque of 123 Nm (91 lb ft).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the nut (5) to a torque of 304 Nm
(224 lb ft).
5. Install the V-belt to the engine. Refer to
Disassembly and Assembly, V Belts Remove and
Install for more information.
i02200446
Crankshaft Front Seal Remove
i02187983
Crankshaft Front Seal - Install

NOTICE
component life.
Removal Procedure
NOTICE
component life.
NOTICE
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
mandates.
Remove the Front Oil Seal that is installed

in the Engine
Illustration 75
g01113392
1. Clean the bore of the housing (1) for the crankshaft

front seal (2) and inspect the bore of the housing
for any damage.
2. Lubricate the crankshaft front seal (2) with clean
engine oil.
3. Position the crankshaft front seal (2) in the bore of
the housing (1) for the crankshaft front seal.
1. If the front cover is still attached to the engine, use

a suitable lever in order to remove the oil seal
from the front cover.
NOTICE
Ensure that the lip of the crankshaft front seal that is
spring loaded is facing toward the inside of the front
housing and that it is square with the bore of the housing for the crankshaft front seal.
Remove the Front Oil Seal from a

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

front seal (2).
1. If the front cover has been removed from the

engine, use a suitable hydraulic press in order to
remove the oil seal from the front cover. Ensure
that the front cover is supported correctly in order
to prevent damage to the cover while the oil seal
is being removed.
Note: Apply clean engine oil on the area of the

crankshaft pulley that will be in contact with the
crankshaft front seal (2).
End By:
a. Install the crankshaft pulley and the V-belt. Refer
to Disassembly and Assembly, Crankshaft Pulley
44
SENR9973-01
i02186336
Housing (Front) - Remove

Removal Procedure
Start By:
a. Remove the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Remove.
b. Remove the crankshaft pulley. Refer to
Disassembly and Assembly, Crankshaft Pulley
NOTICE
component life.
NOTICE
mandates.
Illustration 76
g01129574
Typical example
1. Remove the setscrews and the nuts (5) from the

front 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) and
the 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 is
damaged, use new parts for replacement.
SENR9973-01
45
i02186302
Removal of the Throttle Control
Housing (Front) - Disassemble

Disassembly Procedure
Start By:
a. Remove the engine front housing. Refer to
Disassembly and Assembly, Housing (Front) Remove.
NOTICE
component life.
NOTICE
mandates.
Illustration 77
g01114167
Typical example
1. Remove the spring (5) from the lever (8) for the
throttle control.
2. Loosen the nut (1) and the bolt (4) that secures
the arm (3) to the lever (8) for the throttle control.
Note: Identify the position of the arm in relation to the
lever for installation. Do not remove the nut (1) and
the washers (2) from the bolt (4).
3. Remove the arm (3) from the lever (8).
4. Remove the C-clip (6) from the lever (8).
5. Remove the lever (8) from the front housing (9).
6. Remove the O-ring (7) from lever (8). Discard the
O-ring.
7. Check the components for wear or damage.
Replace any components that are worn or
damaged.
Removal of the linkage for the Fuel

Injection Pump
Note: When the linkage for the fuel injection pump is
removed or the engine front cover is replaced, the
setting for the maximum fuel may be affected.
46
SENR9973-01
Removal of the Stop Control
Illustration 79
g01114517
Typical example
Illustration 78
g01114159
Typical example
1. Remove the spring (10) from the lever assembly

(11).
2. Remove the C-clip (14) from the shaft (12).
3. Remove the shaft (12) and remove the lever
assembly (11) from the engine front housing (9).
4. Remove the O-ring (13) from the shaft (12).
Discard the O-ring.
5. Remove the angleich unit (15) from the lever
assembly (11).
Note: The angleich unit is not installed to the
402C-05, 403C-07, 403C-11 and 404C-15 engines,
or engines that run at a constant speed.
6. Check the components for wear or damage.
damaged.
1. Remove the nut (16) and remove the washer (17)

that secures the lever (18) to the arm (24) for the
stop control.
2. Remove the lever (18) from the arm (24) for the
stop control.
Note: Identify the position of the lever (18) on the
shaft (24) for installation.
3. Remove the nut (19) from the arm (24) for the
stop control. Remove the washer (20) and remove
the spring (21) from the arm (24).
4. Remove the arm (24) for the stop control from the
front housing.
5. Remove the C-clip (23) and the O-ring (22) from
the arm (24). Discard the O-ring.
SENR9973-01
47
Removal of the PTO Cover
Illustration 80
Installation of the Throttle Control
g01114513
Typical example
1. Remove the nuts (25) and the bolts (31) from the
PTO cover.
2. Remove the plates (26) and (30).
Illustration 81
Note: The plate (30) is not installed on 402C-05 or

403C-07 engines.
3. Remove the joint (27) and discard the joint.
g01114382
Typical example
1. Install the O-ring (6) to the shaft of the lever (7).
4. Remove the O-ring (29). Discard the O-ring.
2. Lubricate the O-ring (6) and the shaft of the lever

(7) with clean engine oil. Install the lever (7) into
the front housing (8).
Note: The O-ring (29) is not installed on 402C-05

or 403C-07 engines.
3. Install the C-clip (5) onto the shaft of the lever (7).
5. Check the condition of all parts. Replace any parts

that are damaged or worn.
4. Install the arm for the throttle control (3) onto the
lever (7). Tighten the nut (1) and bolt (4) to a
i02801664
Housing (Front) - Assemble

Assembly Procedure
Note: If the engine front housing is replaced, ensure
that a new emissions label is installed.
Installation of the linkage for the Fuel

Injection Pump
1. If necessary, perform the following procedure to
install the angleich unit (15) to the lever assembly
(11).
48
Illustration 82
SENR9973-01
g01114377
a. Apply 21820117 POWERPART Threadlock to

the first two threads of the angleich unit (18).
b. Install the angleich unit (18) to the lever
assembly (11). Tighten the angleich unit to a
torque of 5 Nm (44 lb in).
Note: Ensure that no 21820117 POWERPART
Threadlock is allowed to contaminate the plunger
assembly of the angleich unit. Contamination of
the plunger assembly will render the angleich unit
inoperative.
Illustration 83
g01114562
Typical example
2. Install the spring (10) to the lever assembly (11).

3. Install the O-ring (13) to the shaft (12). Lubricate
the shaft with clean oil.
4. Position the lever assembly (11) in the front
housing (8). Install the shaft (12) to outside of the
front housing (8).
Note: Ensure that the groove for the C-clip (16) in
the shaft (12) is positioned between the boss (15) on
the front housing and the cast retainer (17) on the
front housing (8).
5. Install the C-clip (14) to the shaft (12).
SENR9973-01
49
3. Place the spring (24) and the washer (23) onto the
arm (27). Install the nut (22) onto the arm (27).
4. Install the lever (21) onto the arm (27).
5. Install the washer (20) and the nut (19) onto the
arm (27). Tighten the nuts (19) and (22) to a
Installation of the PTO Cover
Illustration 84
g01114380
Typical example
6. Attach the spring (10) to the notch on the inside

of the front housing (8).
7. Install the spring (9) to the lever assembly (11).
8. Attach the spring (9) to the lever (7).
Installation of the Stop Control
Illustration 86
g01114607
Typical example
Note: The O-ring (32) and the plate (33) are not
installed on the 402C-05 and 403C-07 engines.
1. For 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, install the O-ring
(32) to the groove in the front housing (31).
2. Install a new joint (30) to the rear of the front
housing.
3. For 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, install the plates
(29) and (33).
For 402C-05 and 403C-07 engines, install the
plate (29).
Illustration 85
g01114606
Typical example
1. Install the C-clip (26) and install the O-ring (25) to

the arm (27).
2. Lubricate the O-ring (25) and the shaft of the arm
(27) with clean oil. Install the arm assembly (27) to
the front housing.
4. Install the nuts (28) and the bolts (34) for the PTO
cover. Tighten the nuts to a torque of 13 Nm
(10 lb ft).
End By:
a. Install the front housing to the engine. Refer to
Disassembly and Assembly, Housing (Front)
Install for more information.
50
SENR9973-01
b. Check the maximum engine speed at no load.

Refer to Testing and Adjusting, Engine Speed Check for more information.
i02801665
Housing (Front) - Install

Table 7
Required Tools
Part Number
Part Description
Qty
21825620
Seal Guide
402C-05, 403C-07, 403C-11
and 404C-15 engines
21825621
Seal Guide
403C-15, 403C-17, 404C-22
and 404C-22T engines
NOTICE
component life.
1. Clean the front housing assembly (4) thoroughly.
Illustration 87
g01113288
3. Align the locating pin (2) with the locating hole on

the oil pump cover (1). Ensure that the oil pump
cover is concentric to the idler gear assembly.
2. For 402C-05, 403C-07, 403C-15 and 404C-11

engines, install the 21825620 Seal Guide (6) to
the crankshaft.
4. Install a new joint to the front of the cylinder block

(7).
For 403C-15, 403C-17, 404C-22 and 404C-22T

engines, install the 21825621 Seal Guide (6) to
the crankshaft.
5. Turn the mechanical stop lever (3) to the full

clockwise position so that the spring is held under
tension. Observe the position of the linkage for
the fuel injection pump (not shown) in the front
housing.
6. Position the front housing (4) on the front of
cylinder block (7). Guide the linkage for the fuel
injection pump into position so that the link is free
to move inside the aperture on the cylinder block
for the fuel injection pump.
7. Align the front housing (4) with the dowels in the
front of the cylinder block (7). Press the front
housing into position. Release the stop lever (3).
8. Install the fasteners (5) finger tight.
9. Tighten the fasteners (5) to a torque of 10 Nm
(7 lb ft).
10. Remove seal guide (6) from the crankshaft.
SENR9973-01
51
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, Crankshaft Pulley - Remove and
Install.
b. Install the fuel injection pump. Refer to
Disassembly and Assembly, Fuel Injection Pump
- Install.
i02187994
Crankcase Breather - Remove

and Install
Removal Procedure (Naturally
Aspirated Engines)
NOTICE
component life.
Illustration 88
NOTICE
mandates.
The two cylinder, the three cylinder and the four
cylinder engines have different crankcase breathers.
The removal procedure is identical for all models.
g01114038
Typical example

breather cover (2) from the valve mechanism
cover (10).
2. Remove the spring (3). Remove the diaphragm
assembly (4).
3. Clean the vent hole (6). Clean the cavity (5) for
the breather assembly in the valve mechanism
cover (10).
4. If necessary, remove the setscrews (7). Remove
the plate (8) and remove the gauze (9).
5. Clean all parts and inspect all parts. Replace any
parts that are worn or damaged.
Removal Procedure (Turbocharged

Engines)
NOTICE
component life.
52
SENR9973-01
NOTICE
mandates.
5. If necessary, remove the setscrews (9). Remove

the plate (10) and remove the gauze (11).
6. Clean all parts and inspect all parts. Replace any
parts that are worn or damaged.
Installation Procedure (Naturally

Aspirated Engines)
NOTICE
component life.
NOTICE
Make sure that the components of the breather assembly are installed correctly. Engine damage may
occur if the breather assembly is not working properly.
The two cylinder, the three cylinder and the four
cylinder engines have different crankcase breathers.
The installation procedure is identical for all models.
Illustration 89
g01114041
Typical example

breather cover (2) from the valve mechanism
cover (12).
2. Remove the spring (3). Remove the diaphragm
assembly (4).
3. Remove the adapter (6). Remove the joint (7).
Clean the vent hole (5).
4. Clean the cavity (8) for the breather assembly in
the valve mechanism cover (12).
Illustration 90
Typical example
g01114038
SENR9973-01
53
1. If necessary, install a new gauze (9). Apply a

bead of 1861108 POWERPART silicon jointing
compound to the mating face of the plate in the
valve mechanism cover (10). Install the plate (8).
a torque of 1.5 Nm (13 lb in).
2. Install a new diaphragm assembly (4) into cavity
(5) of the valve mechanism cover. Install a new
spring (3).
3. Install the breather cover (2) and the four
of 3 Nm (27 lb in).
(Turbocharged Engines)
NOTICE
component life.
NOTICE
Make sure that the components of the breather assembly are installed correctly. Engine damage may
occur if the breather assembly is not working properly.
Illustration 91
g01114041
Typical example
1. If necessary, install a new gauze (11). Apply a

bead of 1861108 POWERPART silicon jointing
compound to the mating face of the plate in the
valve mechanism cover (12). Install the plate (10).
a torque of 1.5 Nm (13 lb in).
2. Install a new joint (7). Install the adapter (6).
Note: the connection on the adapter should face to
the rear of the engine. The vent hole (5) should face
upward.
3. Install a new diaphragm assembly (4) into the
adapter (6). Install a new spring (3).
4. Install the breather cover (2) and the four
of 3 Nm (27 lb in).
54
SENR9973-01
i02801666
Valve Mechanism Cover Remove and Install
1. Remove the setscrews (2) from the connector

(3) and remove the connector from the valve
mechanism cover (6). Remove the gasket (4).
Discard the gasket.
2. Remove the setscrews (1) and remove the cap
nuts (5) that attach the valve mechanism cover (6)
to the housing (7) for the rocker shaft assembly.
Removal Procedure
NOTICE
component life.
3. Remove the valve mechanism cover (6) from the

housing (7) for the rocker shaft assembly. Remove
the joint (8) from the valve mechanism cover (6).
Inspect the joint. If the joint is worn or damaged,
use a new part for replacement.
NOTICE
mandates.
engine.
NOTICE
component life.
engine.
1. Clean all surfaces thoroughly.
Note: The inlet manifold is part of the valve

mechanism cover.
Illustration 93
g00819350
Typical example
Illustration 92
Typical example
g00819350
2. Install the joint (8) to the valve mechanism cover

(6).
3. Install the valve mechanism cover (6) to the
housing (7) for the rocker shaft assembly.
SENR9973-01
55
4. Install the setscrews (1) and install the cap nuts

(5).
5. For 402C-05 and 403C-07 engines, tighten the
setscrews and cap nuts to a torque of 10 Nm
(7.5 lb ft).
setscrews and the cap nuts to a torque of 11 Nm
(8.1 lb ft).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the setscrews and the cap nuts
6. Install a new gasket (4) to the valve mechanism
cover (6). Install the connector (3) to the valve
mechanism cover (6) with setscrews (2). Tighten
i02187973
Rocker Shaft and Pushrod Remove

Removal Procedure
Start By:
a. Remove the engine oil line. Refer to Disassembly
and Assembly, Engine Oil Line - Remove and
Install.
b. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
NOTICE
component life.
NOTICE
mandates.
engines. The illustration shows the four cylinder
engine.
Illustration 94
g00827968
Typical example
1. Loosen the nuts and the adjustment screws (3)

on the rocker arms in order to release the tension
from the rocker shaft assembly (4).
2. Remove the nuts (2) and the setscrews (1) from
the rocker shaft assembly (4).
3. Remove the rocker shaft assembly (4) from
cylinder head (7).
4. Remove the pushrods (6) from the cylinder head.
Mark the pushrods for installation. Inspect the
pushrods for wear or for damage. If the pushrods
are damaged, use new parts for replacement.
5. Remove the caps (not shown) from the top of the
valve stems (5). Mark the caps for installation.
Inspect the caps for wear or for damage. If the
caps are worn or damaged, use new parts for
replacement.
6. Remove the joint (9) from the base of the rocker
shaft assembly (8). Inspect the joint. If the joint is
worn or damaged, use a new part for replacement.
56
SENR9973-01
i02801667
Rocker Shaft - Disassemble

Disassembly Procedure (402C-05,
403C-07, 403C-11 and 404C-15
engines)
Start By:
a. Remove the rocker shaft and the pushrods. Refer
to Disassembly and Assembly, Rocker Shaft and
Pushrod - Remove.
NOTICE
4. In order to remove the rocker shaft (4), install a

suitable setscrew with a M8 x 1.25 thread into the
end of the rocker shaft. Use the setscrew to pull
the rocker shaft (4) from the base of the rocker
shaft (8).

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

component life.
Note: Place an identification mark on each of the

components for installation.
6. Remove the adjustment screws (1) and the nuts
(2) from rocker arms (3).
7. Inspect all of the components for wear or for
damage. Refer to the Specifications Manual,
Rocker Shaft. If any of the components are worn
or damaged, use new parts for replacement.
Disassembly Procedure (403C-15,

403C-17, 404C-22 and 404C-22T
engines)
Start By:
a. Remove the rocker shaft and the pushrods. Refer
Pushrod - Remove.
Illustration 95
g01124594
Typical example
1. Remove the threaded plug (6) from the base of

the rocker shaft (8).
2. Remove the O-ring (5) from the threaded plug (6).
Discard the O-ring.
3. On 403C-07, 403C-11 and 404C-15 engines,
remove the setscrew (7) that locates the rocker
shaft (4) to the base of the rocker shaft (8).
NOTICE
component life.
SENR9973-01
57
i02801668
Rocker Shaft - Assemble

Assembly Procedure (402C-05,
403C-07, 403C-11 and 404C-15
engines)
NOTICE
component life.
Note: The assembly procedure is similar for the
engines. The illustration shows a three cylinder
engine.
1. Lubricate the adjustment screw (1) with clean
engine oil. Install the adjustment screw (1) and the
nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
Illustration 96
g01124595
Typical example
1. In order to remove the rocker shaft (4), install a

suitable M8 setscrew into the end of the rocker
shaft. Use the setscrew to pull the rocker shaft (4)
from the base of the rocker shaft (5).

2. Remove the rocker arms (3), the washers (7), and
the springs (8).
Note: Place an identification mark on each of the
components for installation.
3. Remove the O-ring (6) from the rocker shaft (4).
Illustration 97
g01124596
Typical example
2. Lubricate the rocker shaft (4) with clean engine

oil. Position the end of the rocker shaft into the
bore in the base of the rocker shaft (8).
4. Remove the adjustment screws (1) and the nuts

(2) from rocker arms (3).
For 402C-05 engines, align the two recesses (not

shown) in the rocker shaft with the holes in the
base of the rocker shaft (8).
5. Inspect all of the components for wear or for

damage. Refer to the Specifications Manual,
Rocker Shaft. If any of the components are worn
or damaged, use new parts for replacement.
For 403C-07, 403C-11 and 404C-15 engines,

align the hole (10) in the rocker shaft with the hole
(9) in the base of the rocker shaft (8).
58
SENR9973-01
3. Gradually insert the rocker shaft (4) into the base

of the rocker shaft (8). Install the rocker arm (3).
Assembly Procedure (403C-15,

403C-17, 404C-22 and 404C-22T
engines)

NOTICE

component life.

Note: The assembly procedure is similar for the three

cylinder and the four cylinder engines. The illustration
shows a four cylinder engine.
4. Continue to insert the rocker shaft (4) and install

the following components to the rocker shaft:
Rocker arm (3)
1. Lubricate the adjustment screw (1) with clean

engine oil. Install the adjustment screw (1) and the
nut (2) to the rocker arm (3). Repeat the process
for the remaining rocker arms.
Washer (9)
Spring (10)
Washer (9)
Rocker arm (3)
5. Repeat Steps 4 and 3 in order to install the
remaining components.
6. Ensure that the rocker shaft (4) is fully engaged
into the base of the rocker shaft (8). Check that
the alignment of the rocker shaft is correct.
7. For 403C-07, 403C-11 and 404C-15 engines,
apply 21820117 POWERPART Threadlock to
the first two threads of the setscrew (7). Install
the setscrew (7) in the hole (9) in the base of the
rocker shaft. Tighten the setscrew.
Note: Ensure that no 21820117 POWERPART
Threadlock is allowed to contaminate the oil gallery
in the rocker shaft.
8. Install a new O-ring (5) to the threaded plug (6).
9. Install the threaded plug (6) to the base of the
rocker shaft (9). Tighten the plug to a torque of
15 Nm (11 lb ft).
End By:
a. Install the rocker shaft and the pushrods. Refer to
Pushrod - Install.
Illustration 98
g01113618
Typical example
2. Install a new O-ring (8) onto the rocker shaft (4).

Lubricate the rocker shaft with clean engine oil.
3. Position the end of the rocker shaft (4) into the
bore in the base of the rocker shaft (7). Align the
recesses (5) on the rocker shaft with the holes (6)
in the base of the rocker shaft (7).
SENR9973-01
59
4. Gradually insert the rocker shaft (4) into the base

of the rocker shaft (7). Install the rocker arm (3).

5. Continue to insert the rocker shaft (4) and install
the following components to the rocker shaft:
Rocker arm (3)

Washer (9)
Illustration 99
Spring (10)
g00827968
Typical example
Washer (9)
1. Install the joint (9) to the base of the rocker shaft

assembly (8).
Rocker arm (3)

6. Repeat Steps 4 and 3 in order to install the
remaining components.
7. Ensure that the rocker shaft (4) is fully engaged
into the base of the rocker shaft (7). Check that
the recesses (5) on the rocker shaft are aligned
with the holes (6) in the base of the rocker shaft.
End By:
a. Install the rocker shaft and the pushrods. Refer to
Pushrod - Install.
i02801669
Rocker Shaft and Pushrod Install

2. Lubricate the pushrods (6) with clean engine oil.

Install the pushrods (6) in the cylinder head (7).
Ensure that the pushrods are installed correctly in
the socket of the valve lifters.
Note: If the pushrods have been used, ensure that
the pushrods are installed in original positions.
3. Lubricate the top of the valve stems (5) with clean
engine oil. Install the caps (not shown) on the top
of the valve stems.
Note: If the caps have been used, ensure that the
caps are installed in original positions.
4. Lubricate the adjustment screws (3) on each
rocker arm with clean engine oil before installation.
Install the rocker shaft assembly (4) to the cylinder
head (7).
Note: Ensure that the ends of the adjustment screws
on each rocker arm are correctly seated in the ends
of the pushrods (6).
5. Install the setscrews (1) and the nuts (2).
NOTICE
6. Evenly tighten the nuts (2).

component life.
Note: The tightening sequence moves from the

center of the rocker shaft outward.

engine.
7. For 402C-05 and 403C-07 engines, tighten the

setscrews (1) and the nuts (2) to a torque of
10 Nm (89 lb in).
60
SENR9973-01

setscrews (1) to a torque of 10 Nm (89 lb in).
Tighten the nuts (2) to a torque of 23 Nm (17 lb ft).
For 403C-15, 403C-17, 404C-22 and 404C-22T
engines, tighten the setscrews (1) to a torque of
10 Nm (89 lb in). Tighten the nuts (2) to a torque
8. Adjust the valve lash. Refer to Testing and
Adjusting, Engine Valve Lash - Inspect/Adjust for
the correct procedure to adjust the valve lash.
End By:
a. Install the valve mechanism cover. Refer to
NOTICE
component life.
NOTICE
mandates.
b. Install the engine oil line. Refer to Disassembly

and Assembly, Engine Oil Line- Remove and
Install.
i02801670
Cylinder Head - Remove

Removal Procedure
Start By:
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
Illustration 100
g00828137
Typical example
b. Remove the exhaust manifold. Refer to

Disassembly and Assembly, Exhaust ManifoldRemove and Install.
c. Remove the valve mechanism cover. Refer to
d. Remove the rocker shaft and the pushrods. Refer
Pushrod - Remove.
e. Remove the fuel injection lines. Refer to
f. Remove the fuel injectors. Refer to Disassembly
and Assembly, Fuel Injectors - Remove.
g. Remove the oil line. Refer to Disassembly and
Assembly, Engine Oil Line - Remove and Install.
Illustration 101
Typical example for the 2 cylinder head
g01116726
SENR9973-01
61
3. Remove the cylinder head gasket from the cylinder

block (3) or the cylinder head (2). Do not reuse the
old cylinder head gasket for the cylinder head (2).
Note: Place the cylinder head on a surface that will
not scratch the face of the cylinder head.
Note: The old gasket for the cylinder head should
be used for identification. Head gaskets of different
thickness are available. Refer to Specifications,
Cylinder Head. The piston height relative to the
cylinder head is controlled by the thickness of
the head gasket. Refer to Testing and Adjusting,
Cylinder Head - Inspect.
Illustration 102
g00854316
4. If necessary, remove the cylinder head dowels

from the cylinder block (3). Use a suitable puller to
remove the cylinder head dowels.
5. Inspect the cylinder head (2). Refer to Testing and
Adjusting, Cylinder Head - Inspect and Testing
and Adjusting, Valve Depth - Inspect.
i02801671
Cylinder Head - Install

Illustration 103
g01109567
1. Loosen the cylinder head bolts (1) in reverse order

as this will help prevent distortion of the cylinder
head (2).
NOTICE
component life.
For the 402C-05 engine, gradually loosen the

cylinder head bolts (1) in the reverse order that is
shown in illustration 101.
For the 403C-07, 403C-11, 403C-15 and 403C-17
engines, gradually loosen the cylinder head bolts
(1) in the reverse order that is shown in illustration
102.
For the 404C-15, 404C-22 and 404C-22T engines,
gradually loosen the cylinder head bolts (1) in the
reverse order that is shown in illustration 103.
Note: Do not use a pry bar to separate the cylinder
head from the cylinder block . Use a rubber mallet to
loosen the cylinder head from the cylinder block.
2. Attach a suitable lifting device to the cylinder
head (2). Carefully lift the cylinder head (2) off the
cylinder block (3).
Note: Avoid contamination of the cylinder bores with
coolant or with debris.
Illustration 104
g00828137
Typical example
1. Thoroughly clean the top of cylinder block (3) and

the bottom of the cylinder head (2). Ensure that
there is no debris in the cylinder bores.
2. If necessary, install the dowels (6) to the cylinder
block (3).
62
Illustration 105
SENR9973-01
g00828396
Typical example
Illustration 106
g01116726
3. Install suitable guide studs (not shown) to the

cylinder block (3). Place the cylinder head gasket
(4) over the guide studs and align the gasket (4)
with the dowels (6) in the cylinder block (3).
Note: The old gasket for the cylinder head should
be used for identification. Head gaskets of different
thickness are available. Refer to Specifications,
Cylinder Head. The piston height relative to the
cylinder head is controlled by the thickness of
the head gasket. Refer to Testing and Adjusting,
Cylinder Head - Inspect.
Note: A four digit number is stamped on cylinder
head gasket (4) at location (5). This number should
face the cylinder head in order to ensure the correct
positioning of the cylinder head gasket. Do not use
any gasket sealant or compound on the cylinder
head gasket.
Illustration 107
g00854316
4. Attach a suitable lifting device to the cylinder head

(2).
5. Install the cylinder head (2) to the cylinder block
(3). Check that the cylinder head is positioned
correctly.
6. Lubricate the cylinder head bolts (1) with clean
engine oil.
Illustration 108
g01109567
7. Install the cylinder head bolts (1) finger tight.

For 402C-05 engines, tighten the cylinder head
bolts to a torque of 36.5 Nm (26.9 lb ft). Use the
numerical sequence that is shown in illustration
106.
SENR9973-01
63

107.
Lifter Group - Remove and

Install

107.
Removal Procedure

cylinder head bolts to a torque of 100.5 Nm
(74.1 lb ft). Use the numerical sequence that is
108.
For 404C-22 and 404C-22T engines, tighten the
cylinder head bolts to a torque of 100.5 Nm
(74.1 lb ft). Use the numerical sequence that is
i02187977
Start By:
a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head Remove.
NOTICE
component life.
Note: Mark the original location of the lifters for later
installation.
End By:
a. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, Rockershaft and
Pushrods - Remove and Install.
b. Install the valve mechanism cover. Refer to
c. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install.
d. Install the oil line. Refer to Disassembly and
Assembly, Engine Oil Line - Remove and Install.
e. Install the exhaust manifold. Refer to Disassembly
and Assembly, Exhaust Manifold - Remove and
Install.
f. Install the fuel injectors. Refer to Disassembly and
Assembly, Fuel Injectors - Remove and Install.
g. Install the fuel injection lines. Refer to Disassembly
and Assembly, Fuel Injection lines - Remove and
Install.
Illustration 109
g01110885
Typical example
1. Use a suitable telescopic magnet (1) to remove

the lifter (2) from the cylinder block.
2. Inspect the lifter (2) for wear or damage. If the
lifter (2) is worn or damaged, use a new part for
replacement.
3. Repeat Steps 1 and 2 for the remaining lifters.
64
SENR9973-01
c. Remove the fuel priming pump. Refer to

Disassembly and Assembly, Fuel Priming Pump
- Remove.
NOTICE
component life.
NOTICE
component life.
NOTICE
mandates.
Illustration 110
g01116687
Typical example
1. Ensure that the lifter (2) is clean and that the oil
hole (3) in the lifter (2) is not restricted. Lubricate
the lifter (2) with clean engine oil and install the
lifter (2) in the cylinder block.
Note: Ensure that the lifters (2) are installed in the
original location. If the camshaft has been replaced,
install new lifters (2). Do not install worn lifters to a
new camshaft.
2. Repeat Step 1 for the remaining lifters.
Illustration 111
g00828467
Typical example
End By:
a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head Install.
i02801672
Camshaft - Remove
1. Remove the slider (1) from the camshaft gear (4).

2. Before the idler gear is removed, rotate the
crankshaft until the timing marks (2) on the
following components are aligned.
Crankshaft gear (3)

Camshaft gear (4)
Removal Procedure
Start By:
a. Remove the lifters. Refer to Disassembly and
Assembly, Lifter Group - Remove and Install.
b. Remove the engine front housing. Refer to
Disassembly and Assembly, Housing (Front) Remove.
Idler gear (5)

3. Remove the idler gear (5). Refer to Disassembly
and Assembly, Engine Oil Pump - Remove.
SENR9973-01
65
6. Carefully remove the camshaft assembly (10)

from the cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft
bearings.
7. Inspect the components for wear or damage.
Refer to specifications, Camshaft for details of
the camshaft lobes. Replace any components that
are worn or damaged.
i02196165
Camshaft - Disassemble
Illustration 112
g00828468
Typical example
4. Rotate the camshaft gear (4) in order to align the

access hole (8) in the camshaft gear with the
fastener for the camshaft retainer (9).
Note: The two cylinder and the three cylinder engines
have a different type of camshaft retainer (9) to the
four cylinder engines. The removal procedure is
identical for all models.
For 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, remove the outer
setscrew (6) and remove the allen head screw (7).
Start By:
a. Remove the camshaft assembly. Refer to
Disassembly and Assembly, Camshaft Remove.
NOTICE
component life.
For 404C-22 and 404C-22T engines, remove the

outer setscrew (6) and remove the setscrew (7)
from the camshaft retainer (9).
5. Remove the camshaft retainer (9).
Illustration 114
g01113616
Typical example
Illustration 113
Typical example
g01129576
1. Use a suitable puller to remove the camshaft gear

(5) from the camshaft (1).
Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
governor flyweights during disassembly.
66
SENR9973-01
2. Remove the spacer (4) and the woodruff key (2)

from the camshaft (1).
3. Use a suitable puller to remove the front camshaft
bearing (3) from the camshaft (1).
Note: Identify the orientation of the camshaft bearing
(3) for installation.
4. Inspect all of the components for wear or damage.
damaged.
i02196164
Camshaft - Assemble
Note: Ensure that the camshaft bearing (3) is

installed in the correct orientation. The camshaft
bearing should be pressed squarely onto the
camshaft or damage to the bearing may occur.
2. Install the spacer (4) and the woodruff key (2) to
the camshaft (1).
3. Align the camshaft gear (5) with the woodruff key
(2) on the camshaft (1). Use a suitable press to
install the camshaft gear to the camshaft.
Note: The camshaft gear should be positioned on a
suitable support in order to prevent damage to the
governor flyweights during installation.
End By:
a. Install the camshaft assembly. Refer to
Disassembly and Assembly, Camshaft - Install.
Assembly Procedure
i02801686
NOTICE
Camshaft - Install

component life.
NOTICE
component life.
1. Ensure that the camshaft is clean. Lubricate the
camshaft with clean engine oil.
Illustration 115
g01113616
Typical example
1. Ensure that the camshaft (1) is clean. Lubricate

the front end of the camshaft with clean engine oil.
Use a suitable press to install the front camshaft
bearing (3) to the camshaft.
Illustration 116
g01129587
SENR9973-01
67
2. Carefully install the camshaft assembly (10) into

the engine cylinder block (11). Be careful not to
damage the lobes of the camshaft or the camshaft
bearings.
Crankshaft gear (3)

Camshaft gear (4)
Idler gear (5)
Number one piston will now be in the top dead
center position.
6. Install the slider (1) to the camshaft (4).
Note: Ensure that the notch on the base of the slider
(1) is engaged on the pin of the camshaft gear (4).
End By:
Illustration 117
g00828468
a. Install the engine front housing. Refer to

Disassembly and Assembly, Housing (Front) Install.
b. Install the fuel priming pump. Refer to Disassembly
and Assembly, Fuel Priming Pump - Install.
Typical example
3. Install the camshaft retainer (9).

Note: The two cylinder and the three cylinder engines
have a different camshaft retainer (9) and fasteners
(6) and (7), to the four cylinder engines. The removal
procedure is similar for all models.
4. Align the holes in the camshaft retainer (9) with
the holes in the cylinder block (11).
For 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, install the outer
setscrew (6) and install the allen head screw (7).
For 404C-22 and 404C-22T engines, install the
setscrews (6) and (7).
Torque both fasteners to 11 Nm (8 lb ft).
c. Install the lifters. Refer to Disassembly and

Assembly, Lifter Group- Remove and Install.
i02186340
Engine Oil Pan - Remove and

Install
Removal Procedure
NOTICE
component life.
NOTICE
mandates.
Illustration 118
g00828467
5. Install the idler gear (5). Refer to Disassembly and

Assembly, Engine Oil Pump - Install.
Note: When you install the idler gear, ensure
that timing marks (2) are aligned on the following
components.

four cylinder engines have different engine oil pans.
The removal procedure is identical for all models.
68
Illustration 119
SENR9973-01
g00820013
Illustration 120
Typical example
Typical example
1. Remove the drain plugs (5) from the engine oil pan
(2). Drain the engine oil into a suitable container
for storage or disposal. Refer to Operation and
Maintenance Manual, Refill Capacities for the
approximate capacity of the lubricating oil system.
1. Clean all surfaces thoroughly.
2. Remove the sealing washers (3) from the drain

plugs (5). Discard the sealing washers.
3. Remove the setscrews (4) for the engine oil pan
(2).
4. Remove the engine oil pan (2) from the engine.
5. Remove the joint (1) from the engine oil pan and
the cylinder block. Discard the joint.
g00820013
2. Install a new joint (1) to the engine. Install the

engine oil pan (2) to the engine.
3. Install the setscrews (4) for the engine oil pan (2).
Tighten the setscrews for the engine oil pan to a
4. Install the drain plugs (5) and new sealing washers
(3) to the oil pan (2). Tighten the drain plugs to a
5. Fill the engine oil pan to the correct level that is
indicated on the engine oil level gauge. Refer
Capacities for more information.
i02189003
NOTICE
component life.
four cylinder engines have different engine oil pans.
The installation procedure is identical for all models.
Pistons and Connecting Rods

- Remove
Removal Procedure
Start By:
a. Remove the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Remove.
b. Remove the engine oil pan. Refer to Disassembly
Install.
c. Remove the oil suction pipe. Refer to Disassembly
and Assembly, Engine Oil Pump - Remove.
SENR9973-01
69
NOTICE
component life.
1. Position the piston that is being removed in the
bottom center position.
8. Keep connecting rods (1) and connecting rod caps

(5) together. Ensure that the identification marks
are on the connecting rod and on the connecting
rod cap. This will ensure that the piston is installed
into the correct cylinder in the cylinder block.
9. Repeat Steps 1 through 8 for removing the
remaining pistons and connecting rods.
i02189019

- Disassemble
Start By:
a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Pistons and
Connecting Rods - Remove.
Illustration 121
g00829370
Typical example
2. Remove the carbon buildup from the inner surface

of the top of the cylinder bore.
3. Ensure that the connecting rod and the cap are
correctly marked to the cylinder.
NOTICE
Removal of the piston pin bushing must be carried
out by personnel with the correct training. Also special machinery is required. For more information refer
to your authorized Perkins dealer or your Perkins distributor.
Note: Do not punch the connecting rod or stamp the

connecting rod assembly as this may cause damage.
NOTICE
4. Remove the nuts (6) from the connecting rod (1).

component life.
5. Remove the connecting rod cap (5) with the

bearing shell (3).
Note: Use tape or rubber tubing on connecting rod
bolts (2) to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the
crankshaft journals.
6. Push the piston and connecting rod (1) away from
the crankshaft until the piston rings are out of the
cylinder bore. Remove the piston from the cylinder
block.
Note: Make a mark under the piston on the pin boss
in order to identify the cylinder. Always mark the front
pin boss to aid installation.
7. Remove connecting rod bearings (3) from
connecting rod (1) and connecting rod cap (5).
70
Illustration 122
SENR9973-01
g01114004
Illustration 123
g01114007
Typical example
Typical example
1. Use suitable pliers in order to remove the circlips

(2).
3. Use a suitable ring expander in order to remove

the piston rings (7) and (6), and the oil control ring
(5) from the piston (4).
2. Remove the piston pin (3) from the piston (4).

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

installation.
SENR9973-01
71
5. Use a suitable press and a suitable adapter in

order to remove the piston pin bushing (11) from
the connecting rod (1).
i02189011

- Assemble
Assembly Procedure
NOTICE
component life.
NOTICE
Installation of the piston pin bushing must be carried
out by personnel with the correct training. Also special
machinery is required.
Illustration 124
g01114027
Typical example
1. If the piston pin bushing was removed, refer to

your authorized Perkins dealer or your Perkins
distributor for assistance.
4. Remove the nuts (8) for the connecting rod cap

(9). Remove the connecting rod cap (9) from
the connecting rod (1). Remove the bearing
shells (10) from the connecting rod (1) and the
connecting rod cap (9).
Illustration 125
Typical example
g01114056
Illustration 126
g01114138
Typical example
2. Align the identification marks (2) on the connecting

rod (1) and the piston (5).
72
SENR9973-01
Note: The Shibaura name inside the piston must

align with the stamped number on the connecting rod.
3. Lubricate the piston pin (4) with clean engine oil.
Install the piston pin (4) into the piston (5) and the
connected rod (1).
Note: If the piston pin cannot be installed by hand,
heat the piston to a temperature of 45 5C
(113 9F).
4. Use suitable pliers to install the two circlips (3).
Ensure that the circlips are seated into the grooves
in the piston (5).
Illustration 128
g01114373
typical example
5. Use a suitable ring expander to install the piston

rings onto the piston (5). Use the following
procedure to install the piston rings onto the
piston.
a. Install the oil control ring (6) in the groove that
is lowest on the piston (5). The latch pin (10)
that is on the oil control ring (6) must be inside
the ends of spring (11).
Note: Ensure that the latch pin that is on the oil
control ring is 180 degrees from the oil control ring
gap.
Illustration 127
g01114155
Typical example
Note: Refer to Specifications, Pistons and Rings for

more information on piston identification.
Illustration 129
g01114374
b. Install the intermediate piston ring (7) with the

tapered face into the second groove on the
piston. The step (12) must be toward the top
of the piston.
SENR9973-01
73
c. Install the top piston ring (8) with the barrel

face and the molybdenum insert into the top
groove on the piston.
d. Lubricate the piston rings with clean engine oil.
Position the piston ring gaps (9) at 90 degrees
away from each other.
End By:
a. Install the pistons and the connecting rods.
Refer to Disassembly and Assembly, Piston and
Connecting Rods - Install.
i02801688

- Install
NOTICE
Illustration 130
g01111980
Typical example
4. Use a suitable piston ring compressor (1) in order

to compress the piston rings.

component life.
For the 402C-05 and 403C-07 engines, the piston

ring compressor should be suitable for a piston
67 mm (2.64 inch).
1. Thoroughly clean all of the components.
For the 403C-11 and 404C-15 engines, the piston

ring compressor should be suitable for a piston
77 mm (3.03 inch) in diameter.
Note: Refer to Disassembly and Assembly,

Connecting Rod Bearings - Install for the inspection
procedure of the connecting rod bearings and the
crankshaft connecting rod journals.
2. Apply clean engine oil to the following components:
Crankshaft journals
Inside of the cylinder bores
Piston rings
For the 403C-15, 403C-17, 404C-22 and

404C-22T engines, the piston ring compressor
should be suitable for a piston 84 mm (3.31 inch)
in diameter.
Note: Move the piston rings on the pistons until
the ring openings are separated by approximately
90 degrees. Refer to Disassembly and Assembly,
Pistons and Connecting Rods - Assemble.
Connecting rod bearings

Note: The piston and the connecting rod are matched
to a specific cylinder. Ensure that the connecting rod
and the pistons are installed in the correct cylinder.
Note: Do not punch the connecting rod or stamp the
connecting rod assembly as this may cause damage.
3. Rotate the crankshaft until the bearing journal is
at the bottom center.
Illustration 131
Typical example
g01112036
74
SENR9973-01
5. Put the piston and the connecting rod in the

cylinder bore. Align the identification marks on the
top of the piston to the front of the cylinder block.
Align the identification marks (3) on the side of
the connecting rod to the right side of the cylinder
block.
Note: The right side is determined from the flywheel
end of the engine.
Note: Ensure that the piston ring compressor (1) is
installed correctly in order to allow the piston and the
connecting rod to easily slip into the cylinder block.
Use tape or rubber tubing on the connecting rod bolts
to protect the crankshaft journals.
6. Align the piston and the connecting rod assembly
with the crankshaft. Use a soft faced hammer (2)
to tap the piston into the cylinder bore until the
piston ring compressor (1) comes off the piston.
10. Rotate the crankshaft in order to ensure that no

binding occurs.
End By:
a. Install the oil suction pipe. Refer to Disassembly
and Assembly, Engine Oil Pump- Install.
Install.
c. Install the cylinder head. Refer to Disassembly
and Assembly, Cylinder Head - Install.
i02186176
Connecting Rod Bearings Remove

Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly
Install.
b. Remove the oil supply tube. Refer to Disassembly
and Assembly, Crankshaft - Remove.
Illustration 132
g01116685
Typical example
7. Push the piston and the connecting rod assembly

into the cylinder. Guide the connecting rod
assembly onto the connecting rod journal.
8. Install the connecting rod cap (4) and the
connecting rod nuts (5).
For the 402C-05 and 403C-07 engines, tighten
the nuts (5) for the connecting rod cap (4) to a
NOTICE
component life.
NOTICE
For the 403C-11 and 404C-15 engines, tighten the

nuts (5) for the connecting rod cap (4) to a torque

mandates.
For the 403C-15, 403C-17, 404C-22 and

404C-22T engines, tighten the nuts (5) for the
connecting rod cap (4)to a torque of 52 Nm
(38 lb ft).
Note: The connecting rod and the connecting rod cap

should have matching marks (6) on the right hand
side. Mark the connecting rod (1) and the connecting
rod cap (5), if necessary. The right side of the engine
is determined from the flywheel end.
9. Repeat Steps 1 through 8 for the remainder of the

pistons and connecting rods.
SENR9973-01
75
NOTICE
When the connecting rod caps are installed, ensure
that the identification marks are aligned.
Illustration 133
g01111763
Typical example
1. Rotate the crankshaft until the piston is at the

bottom center. Remove the connecting rod nuts
(4) from the connecting rod bolts (2). Remove the
connecting rod cap (5) from the connecting rod (1).
Illustration 134
g01111763
Typical example
3. Carefully push the connecting rod (1) into the

cylinder bore. Remove the upper bearing shell (3)
of the connecting rod from the connecting rod.
1. Check the clearance between the connecting rod

bearing and the connecting rod bearing journal of
the crankshaft. Install the connecting rod bearings
dry when the clearance checks are made. Refer to
Disassembly and Assembly, Bearing Clearance
- Check for information on bearing clearance
checks.
Note: Use tape or rubber tubing on the connecting

rod bolts to protect the crankshaft journals. The sharp
edges of the connecting rod bolts could damage the
crankshaft journals.
2. Clean the bearing surface of the connecting rod

(1) and the connecting rod cap (5). Ensure that the
number (6) on the connecting rod cap (5) aligns
with the number (6) on the connecting rod (1).
4. Repeat Steps 1 through 3 for the remaining

connecting rod bearings.
3. Clean the upper connecting rod bearing (3) and

lubricate the bearing face with clean engine oil.
2. Remove the lower bearing shell (3) of the

connecting rod bearing from the connecting rod
cap (5).
i02186171
Connecting Rod Bearings Install
4. Clean the lower connecting rod bearing (3) and

lubricate the bearing face with clean engine oil.
Note: Align the tabs on the back of the connecting rod
bearings (3) with the tab grooves in the connecting
rod (1) and the tab grooves on the connecting rod
cap (5).
5. Install the upper connecting rod bearing (3) to the

connecting rod (1).
NOTICE
6. Position the connecting rod (1) against the

crankshaft.

component life.
7. Install the lower connecting rod bearing (3) in the

connecting rod cap (5).
76
SENR9973-01
8. Install the connecting rod cap (5) in position on

the connecting rod (1) and install the nuts (4) to
the connecting rod bolts (2). Refer to Disassembly
and Assembly, Pistons and Connecting Rods Install for the correct torque of the connecting rod
nuts (4).
Crankshaft Main Bearings
Note: The identification marks must face the right

hand side of the engine for the correct installation.
9. Repeat Steps 2 through 8 for the installation of the
remaining connecting rod bearings.
End By:
a. Install the oil supply tube. Refer to Disassembly
and Assembly, Crankshaft - Install.
Install.
i02801692
Crankshaft Main Bearings Remove

Removal Procedure
Start By:
a. Remove the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Remove.
NOTICE
component life.
g00830378
Illustration 135
Note: Mark the halves of the main bearing carriers

for later installation.
1. Remove the setscrews (1) that secure the upper
half of main bearing cap (2) to the lower half of
main bearing cap (7).
2. Separate the upper half of main bearing cap (2)
from the lower half of main bearing cap (7).
Note: Dowels (5) are installed in each bearing cap
in order to align the two halves of the main bearing
carrier.
Note: Thrust washers are only installed on the
403C-15, 403C-17, 404C-22 and 404C-22T engines.
3. For 403C-15 and 403C-17 engines, remove the
lower thrust washers (3).
For 404C-22 and 404C-22T engines, remove the
lower thrust washers (3) and the upper thrust
washer (6).
4. Remove the main bearings (4) from the main
bearing caps.
Crankshaft Bearing (Front)

Table 8
Part Number
27610275
Part Description
Driver Gp
Qty
1
SENR9973-01
77
1. Install the main bearings (4) into the halves of the

main bearing caps.
2. Position the upper half of the main bearing cap (2)
in position on the crankshaft. Position the lower
half ofthe main bearing cap (7) in position on the
crankshaft.
Note: Refer to the identification marks that have
been made on the main bearing carriers for correct
alignment.
Note: Ensure that the dowels (5) are in the correct
position. This will ensure that the two halves of the
main bearing caps are aligned.
Note: Ensure that the lubricating oil holes align with
the oil feed holes in the cylinder block.
Note: Thrust washers are only installed to 403C-15,
403C-17, 404C-22 and 404C-22T engines.
Illustration 136
g01107352
1. Remove the bush for the crankshaft (1). Use

Tooling (2) and a hammer to drive out the bush for
the crankshaft (1) from the inside of the cylinder
block (3).
i02801697
Crankshaft Main Bearings Install
3. For 403C-15 and 403C-17 engines, install the two

lower thrust washers (3).
For 404C-22 and 404C-22T engines, install the
two lower thrust washers (3) and the upper thrust
washer (6).
Note: Ensure that the thrust washers are aligned
correctly and that the oil grooves are facing the
crankshaft.
4. Install the setscrews (1).
For the 402C-05, 403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 engines, tighten the
Crankshaft Main Bearings
For the 404C-22 and 404C-22T engines, tighten

Bush for the Crankshaft (Front)

Table 9
Required Tools
Part Number
27610275
Illustration 137
g00830378
Part Description
Driver Gp
Qty
1
78
SENR9973-01
c. Remove the housing for the crankshaft rear seal.

Refer to Disassembly and Assembly, Crankshaft
Rear Seal - Remove.
d. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump
- Remove.
e. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Pistons and
Connecting Rods - Remove.
NOTICE
component life.
Illustration 138
g01107393
1. Install the bush for the crankshaft (1). Use Tooling

(6) and a hammer to drive in the bush for the
crankshaft (1) from the outside of the cylinder
block (5).
Note: Ensure that the oil supply hole (4) is aligned
with the oil gallery in the cylinder block (5).
Note: Ensure that the chamfered side (3) of the bush
for the crankshaft (1) is facing toward the cylinder
block (5) and that the joint (2) of the bush for the
crankshaft (1) is facing toward the top of the cylinder
block (5).
End By:
a. Install the crankshaft. Refer to Disassembly and
Assembly, Crankshaft - Install.
i02192828
Crankshaft - Remove
Removal Procedure
Start By:
a. Remove the engine oil relief valve. Refer to
Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install.
b. Remove the flywheel. Refer to Disassembly and
Assembly, Flywheel - Remove and Install.
SENR9973-01
Illustration 139
Typical example
1. Remove the bolts (3) from the crankcase cross

member.
2. Remove the two allen head screws (2) that are
recessed. The allen head screws are located at
the rear of the engine.
3. Place the rear of the engine in an upward position.
Attach a suitable lifting device (1) to the crankshaft
and the main bearing assembly (6).
4. Lift the crankshaft (6) and the main bearing
assembly from cylinder block (5). Do not scratch
any of the finished surfaces on the crankshaft.
79
g01107623
80
SENR9973-01
i02801706
Crankshaft - Install
Illustration 140
g01109599
Typical example
NOTICE
Ensure that the oil passages in the main bearings align
with the oil passages in the cylinder block.
1. Lower the crankshaft and the main bearing
assembly (9) into the cylinder block (8). Do
not scratch any of the finished surfaces on the
crankshaft.
2. Align the two setscrew holes (2) in the main
bearing assembly (9) to the two holes in the
cylinder block (6).
3. Install the two allen head screws (3) that are

recessed. The allen head screws are located at
the rear of the engine.
Tighten the allen head screws (3) to a torque of
27 Nm (20 lb ft).
4. Ensure that the three setscrew holes (7) in the
main bearing assembly (9) are aligned to the three
holes (5) in the cylinder block (8).
Note: The third hole in the main bearing assembly
(7) is not shown.
5. Install the three setscrews (4) in the holes in the
cylinder block (5).
SENR9973-01
81
For the 402C-05, 403C-07, 403C-11 and 404C-15

engines, tighten the setscrews (4) to a torque of
27 Nm (20 lb ft).
Bearing Clearance - Check
For the 403C-15, 403C-17, 404C-22 and

404C-22T engines, tighten the setscrews (4) to a
Measurement Procedure
6. Check the crankshaft for end play. Force the

crankshaft toward the front of the engine and
insert a feeler gauge between the rear thrust
washer and the crankshaft. Alternatively, install a
dial indicator to one end of the crankshaft. Force
the crankshaft to the front of the engine and then
force the crankshaft to the rear of the engine.
Record the variation on the dial indicator. Refer
to Specifications, Crankshaft for the maximum
permissible crankshaft end play.
End By:
a. Install the pistons and the connecting rods. Refer
to Disassembly and Assembly, Pistons and
Connecting Rods - Install.
b. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install.
c. Install the housing for the crankshaft rear seal.
Refer to Disassembly and Assembly, Crankshaft
Rear Seal - Install.
d. Install the flywheel. Refer to Disassembly and
e. Install the engine oil relief valve. Refer to
Disassembly and Assembly, Engine Oil Relief
Valve - Remove and Install.
i01996219
Table 10
Required Tools
Part Description
Qty
Plastic Gauge (Green)

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

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

0.102 to 0.229 mm
(0.004 to 0.009 inch)
Plastic Gauge (Yellow)

0.230 to 0.510 mm
(0.009 to 0.020 inch)
NOTICE
component life.
Note: Perkins does not recommend the checking of
the actual bearing clearances particularly on small
engines. This is because of the possibility of obtaining
inaccurate results and the possibility of damaging the
bearing or the journal surfaces. Each Perkins engine
bearing is quality checked for specific wall thickness.
Note: The measurements should be within
specifications and the correct bearings should
be used. If the crankshaft journals and the bores
for the block and the rods were measured during
disassembly, no further checks are necessary.
However, if the technician still wants to measure the
bearing clearances, the use of Plastic Gauge is an
acceptable method. Plastic Gauge is less accurate
on journals with small diameters if clearances are
less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
The technician must be very careful to use Plastic
Gauge correctly. The following points must be
remembered:
82
SENR9973-01
Ensure that the backs of the bearings and the

bores are clean and dry.
Ensure that the bearing locking tabs are properly

seated in the tab grooves.
The crankshaft must be free of oil at the contact

points of the Plastic Gauge.
1. Put a piece of the Plastic Gauge on the crown of

the bearing that is in the cap.
Note: Do not allow the Plastic Gauge to extend over
the edge of the bearing.
2. Use the correct torque-turn specifications in order
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing
when the cap is installed.
Note: Do not turn the crankshaft when the Plastic
Gauge is installed.
3. Carefully remove the cap, but do not remove
the Plastic Gauge. Measure the width of the
Plastic Gauge while the Plastic Gauge is in the
bearing cap or on the crankshaft journal. Refer
to Illustration 141.
Note: When the Plastic Gauge is used, the readings

can sometimes be unclear. For example, all parts of
the Plastic Gauge are not the same width. Measure
the major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, Connecting Rod Bearing Journal and
Specifications Manual, Main Bearing Journal for the
correct clearances.
i02801717
Coolant Temperature Switch Remove and Install

403C-15, 403C-17, 404C-15,
404C-22, and 404C-22T Engines)
NOTICE
component life.
NOTICE
mandates.
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
Maintenance Section.
Illustration 141
g00953605
Typical Example
4. Remove all of the Plastic Gauge before you install

the bearing cap.
SENR9973-01
Illustration 142
83
g00830643
Illustration 143
g01121721
Typical example
Typical example
2. Remove the coolant temperature switch (1) from

the water temperature regulator housing (2).
2. Remove the coolant temperature switch (1) from

the water pump housing (2).
3. Clean the coolant temperature switch. Inspect

the coolant temperature switch (1) for damage. If
the coolant temperature switch is damaged, use
a new part for replacement. For information on
testing the coolant temperature switch for correct
operation, refer to Testing and Adjusting, Coolant
Temperature Switch - Test.
3. Clean the coolant temperature switch. Inspect

the coolant temperature switch (1) for damage. If
the coolant temperature switch is damaged, use
a new part for replacement. For information on
testing the coolant temperature switch for correct
operation, refer to Testing and Adjusting, Coolant
Temperature Switch - Test.
Removal Procedure (402C-05, and

403C-07 Engines)

403C-15, 403C-17, 404C-15,
404C-22, and 404C-22T Engines)
NOTICE
component life.
NOTICE
component life.
NOTICE
mandates.
a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual,
Maintenance Section.
Illustration 144
g00830643
Typical example
1. If a used coolant temperature switch is installed,

apply 21820122 POWERPART Pipe sealant to
the threads of the coolant temperature switch (1).
2.
84
SENR9973-01
3. Install the coolant temperature switch (1) into

the water temperature regulator housing. Tighten
the coolant temperature switch (1) to a torque of
27 Nm (20 lb ft).
Engine Oil Pressure Switch Remove and Install

Manual, Refill Capacities for additional
information.
Removal Procedure

NOTICE
component life.
i02195380
NOTICE
component life.
NOTICE
mandates.
Note: The engine oil pressure switch can be located
in one of two positions. The oil pressure switch can
be located in the valve mechanism cover (1), or in
the cylinder block (2). Refer to Specifications Manual,
Engine Oil Pressure Switch for the correct location.
Illustration 145
g01121721
Typical example
1. If a used coolant temperature switch is installed,

apply 21820122 POWERPART Pipe sealant to
the threads of the coolant temperature switch (1).
2. Install the coolant temperature switch (1) into
the water pump housing (2). Tighten the coolant
temperature switch (1) to a torque of 27 Nm
(20 lb ft).
Manual, Refill Capacities for additional
information.
SENR9973-01
Illustration 146
85
g01130227
Illustration 147
g01130227
Typical example
Typical example
1. If the oil pressure switch is located in the valve

mechanism cover, remove the engine oil pressure
switch.
1. If a used engine oil pressure switch is installed,

apply a thin layer of 21820122 POWERPART
Pipe sealant to the threads of the engine oil
pressure switch.
If the oil pressure switch is located in the cylinder

block, remove the engine oil pressure switch
and adapter assembly. Remove the engine oil
pressure switch from the adapter.
2. Clean the oil pressure switch.
Note: The engine oil pressure switch can be located
in one of two positions. The oil pressure switch can
be located in the valve mechanism cover (1), or in
the cylinder block (2). Refer to Specifications Manual,
Engine Oil Pressure Switch for the correct location.
2. If the oil pressure switch is located in the valve

mechanism cover, install the engine oil pressure
switch (1). Tighten the oil pressure switch to a
torque of 11 Nm (8.1 lb ft).
If the oil pressure switch is located in the cylinder

block (2), install the engine oil pressure switch
to the adapter. Tighten the engine oil pressure
switch to a torque of 23 Nm (16.9 lb ft). Install the
adapter and oil pressure switch assembly to the
cylinder block. Tighten the adapter to a torque of
11 Nm (8.1 lb ft).
86
SENR9973-01
i02801718
Glow Plugs - Remove and

Install
Removal Procedure
Start By:
a. Remove the fuel injection lines, if necessary. Refer
to Disassembly and Assembly, Fuel Injection
Lines - Remove and Install.
Illustration 149
g00820321
Typical example
Disconnect batteries before performance of any

service work.
NOTICE
component life.
1. Install the glow plugs (4) in the cylinder head.

For the 402C-05,402C-07,403C-11 and 404C-15
engines, tighten the glow plugs to a torque of
11.5 Nm (8.5 lb ft).
For the 403C-15,403C-17,404C-22 and 404C-22T
engines, tighten the glow plugs to a torque of
17.5 Nm (13 lb ft).
2. Install the bus bar (3) on the glow plugs (4).
3. Install the washers (2) and the nuts (1) on the
glow plugs (4). Tighten the nuts (1) to a torque
of 1.2 Nm (10.6 lb in).
End By:
a. Install the fuel injection lines, if necessary. Refer to
i02196372
Illustration 148
g00820321
V-Belts - Remove and Install
Typical example
1. Remove the nuts (1) and the washers (2) from the
bus bar (3) on the glow plugs (4).
2. Remove the bus bar (3) from the glow plugs (4).
3. Remove the glow plugs (4) from the cylinder head.
NOTICE
component life.
Removal Procedure
NOTICE
component life.
SENR9973-01
87
1. Check the condition of the V-belt (5). If the

V-belt is worn or damaged, use a new V-belt for
replacement.
2. Install the V-belt (5) in position on the engine.
3. Slide the alternator (3) away from the engine.
Tighten the setscrew (1) and setscrew (2) to
a torque of 25.5 Nm (18.8 lb ft). Tighten the
fasteners (4) to a torque of 25.5 Nm (18.8 lb ft) for
the alternator (3). Refer to Testing and Adjusting,
Belt Tension Chart for more information on the
correct belt tension.
i02801722
Fan - Remove and Install
Illustration 150
g01109566
Typical example
1. Loosen setscrew (1) and setscrew (2). Loosen the

fasteners (4) on the alternator (3).
2. Push the alternator (3) toward the engine and
remove the V-belt (5).
NOTICE
component life.
Illustration 151
Typical example
g01109566

404C-22T Engines)
Start By:
a. Remove the V-Belts. Refer to Disassembly and
88
Illustration 152
Typical example
1. Remove the four setscrews (1) from the fan (2)

and remove the fan (2) from the adapter (4).
2. Remove the four allen head screws (3) that secure
the adapter (4) and the pulley (5) to the water
pump (6).
3. Remove the adapter (4) and the pulley (5) from
the water pump (6).

403C-07, 403C-11, 403C-15,
403C-17 and 404C-15 Engines)
Start By:
SENR9973-01
g01110541
SENR9973-01
Illustration 153
Typical example
1. Remove the four setscrews (1) that secure the fan

(2), the spacer (3) and the pulley (4) to the water
pump (5).
2. Remove the fan (2), the spacer (3) and the pulley
(4) from the water pump (5).
89
g01116343
90
SENR9973-01

and 404C-22T Engines)
Illustration 154
Typical example
1. Install the pulley (5) and the adapter (4) in position

on the water pump (6) and ensure that the
setscrew holes are aligned.
2. Install the four allen head screws (3) in position
on the adapter (4) and align the setscrews with
the setscrew holes in pulley (5) and the setscrew
holes in the water pump (6). Tighten the four allen
head screws (3) to a torque of 10 Nm (7 lb ft).
3. Position the fan (2) so that the setscrew holes
align with the setscrew holes in adapter (4).
4. Install the four setscrews (1) onto the fan (2) and
hand tighten the setscrews.
5. Tighten the four setscrews (1) to a torque of
11 Nm (8 lb ft).
End By:
a. Install the V-Belts. Refer to Disassembly and
Assembly, V-Belts - Remove and Install .
g01110541
SENR9973-01
91

403C-07, 403C-11, 403C-15, 403C-17
g01116343
Illustration 155
Typical example
1. Install the pulley (4), the spacer (3) and the fan (2)
in position on the water pump (5) and ensure that
the setscrew holes are aligned.
2. Install the four setscrews (1) into the fan (2), the
spacer (3) and the pulley (4) and hand tighten the
setscrews.
3. Tighten the four setscrews to a torque of 11 Nm
(8 lb ft).
End By:
Assembly, V-Belts - Remove and Install .
i02196771
Alternator - Remove and Install

Removal Procedure for the 14 AMP
Alternator
Start By:
Note: Disconnect all electrical connections to the
alternator before proceeding. Mark the connections
or identify the connections for future installation.
92
Illustration 156
Typical example
1. Remove the bolt (1), the washer (3) and the nut
(4) from the alternator (2).
2. Remove the setscrew (5) that fastens the
alternator (2) to the engine.
3. Remove the alternator (2) from the engine.

Alternator
Start By:
SENR9973-01
g01122900
SENR9973-01
Illustration 157
Typical example
(4) from the alternator (2).
2. Remove the setscrew (5) that fastens the
alternator (2) to the engine.

Alternator
Start By:
93
g01122906
94
Illustration 158
Typical example
1. Remove the setscrew (6), the washer (5) and the

spacer (1) from the alternator (2).
2. Remove the setscrew (4) and the washer (3) that
fastens the alternator (2) to the engine.

Alternator
Start By:
SENR9973-01
g01122919
SENR9973-01
Illustration 159
Typical example
1. Remove the setscrew (1) and the washer (2) from

the alternator (3).
2. Remove the two bolts (6), the two washers (5)
and the two nuts (4) that fasten the alternator (3)
to the engine.

and the 85 AMP Alternator
Start By:
95
g01110800
96
Illustration 160
Typical example
1. Remove the setscrew (2) and the washer (1) from

the alternator (3).
(6) that fastens the alternator (3) to the engine.
SENR9973-01
g01123177
SENR9973-01
97
Installation Procedure for the 14

AMP Alternator
Illustration 161
Typical example
1. Position the alternator (2) on the engine.

2. Install the setscrew (5) that fastens the alternator
(2) to the engine.
3. Install the bolt (1), the washer (3) and the nut (4)
to the alternator (2).
4. Hand tighten the setscrew (5), the bolt (1) and the
nut (4) on the alternator (2).
Note: When you install the alternator, ensure that the
alternator pulley is in alignment with the crankshaft
pulley within one degree.
Note: Reconnect all electrical connections to the
alternator before operating the engine.
End By:
g01122900
98
SENR9973-01

AMP Alternator
Illustration 162
Typical example

2. Install the setscrew (5) that fastens the alternator
(2) to the engine.
to the alternator (2).
4. Hand tighten the setscrew (5), the bolt (1) and the
nut (4) on the alternator (2).
End By:
g01122906
SENR9973-01
99

AMP Alternator
Illustration 163
Typical example

2. Install the setscrew (4) and the washer (3) that
fastens the alternator (2) to the engine.
3. Install the setscrew (6), the washer (5) and the
spacer (1) to the alternator (2).
4. Hand tighten the setscrew (4) and the setscrew
(6) on the alternator (2).
End By:
g01122919
100
SENR9973-01

AMP Alternator
Illustration 164
Typical example

2. Install the two bolts (6), the two washers (5) and
the two nuts (4) that fasten the alternator (3) on
the engine.
3. Install the setscrew (1) and the washer (2) to the
alternator (3).
4. Hand tighten the two bolts (6), the two nuts (4)
and the setscrew (1) on the alternator (3) .
End By:
g01110800
SENR9973-01
101

AMP and the 85 AMP Alternator
g01123177
Illustration 165
Typical example

that fastens the alternator (3) to the engine.
i02801726
Electric Starting Motor Remove and Install
3. Install the setscrew (2) and the washer (1) to the

alternator (3).
4. Hand tighten the bolt (4), the nut (6) and the
setscrew (2) on the alternator (3).
End By:
Removal Procedure
Start By:
a. Disconnect all electrical connections to the
electric starting motor before proceeding. Mark
all connections or identify all connections for later
installation.
102
SENR9973-01
For the 403C-11, 403C-15, 403C-17, 404C-15,

404C-22 and 404C-22T engines, the electric
starting motor is secured to the engine with bolts,
washers and nuts (not shown).
For the 402C-05 and 403C-07 engines, the
electric starting motor is secured to the engine
with setscrews and washers.
Tighten the fasteners to a torque of 50 Nm
(36.9 lb ft).
End By:
Illustration 166
g01117494
Typical example
1. Remove the fasteners (1) that secure the electric

starting motor (2) to the engine.
For the 403C-11, 403C-15, 403C-17, 404C-15,
404C-22 and 404C-22T engines, the electric
starting motor is secured to the engine with bolts,
washers and nuts (not shown).
For the 402C-05 and 403C-07 engines, the
electric starting motor is secured to the engine
with setscrews and washers.
2. Remove the electric starting motor (2) from the
engine.
Illustration 167
g01117494
Typical example
1. Install the electric starting motor (2) in position on

the engine.
2. Install the fasteners (1) that secure the electric
starting motor (2) to the engine.
a. Reconnect all electrical connections to the electric

starting motor before you operate the engine.
SENR9973-01
103
Index Section
Index
A
Alternator - Remove and Install ............................. 91
Installation Procedure for the 14 AMP
Alternator.......................................................... 97
Alternator.......................................................... 98
Alternator.......................................................... 99
Alternator........................................................ 100
Installation Procedure for the 65 AMP and the 85
AMP Alternator............................................... 101
Removal Procedure for the 14 AMP Alternator.. 91
Removal Procedure for the 65 AMP and the 85
AMP Alternator................................................. 95
B
Bearing Clearance - Check ................................... 81
Measurement Procedure ................................... 81
C
Camshaft - Assemble ............................................ 66
Assembly Procedure.......................................... 66
Camshaft - Disassemble ....................................... 65
Disassembly Procedure ..................................... 65
Camshaft - Install................................................... 66
Installation Procedure ........................................ 66
Camshaft - Remove............................................... 64
Removal Procedure ........................................... 64
Connecting Rod Bearings - Install ......................... 75
Connecting Rod Bearings - Remove ..................... 74
Coolant Temperature Switch - Remove and
Install ................................................................... 82
Installation Procedure (402C-05, and 403C-07
Engines) ........................................................... 84
Installation Procedure (403C-11, 403C-15,
403C-17, 404C-15, 404C-22, and 404C-22T
Engines) ........................................................... 83
Removal Procedure (402C-05, and 403C-07
Engines) ........................................................... 83
Removal Procedure (403C-11, 403C-15, 403C-17,
404C-15, 404C-22, and 404C-22T Engines) ... 82
Crankcase Breather - Remove and Install............. 51
Installation Procedure (Naturally Aspirated
Engines) ........................................................... 52
Installation Procedure (Turbocharged
Engines) ........................................................... 53
Removal Procedure (Naturally Aspirated
Engines) ........................................................... 51
Removal Procedure (Turbocharged Engines) ... 51
Crankshaft - Install.................................................
Installation Procedure ........................................
Crankshaft - Remove.............................................
Removal Procedure ...........................................
Crankshaft Front Seal - Install ...............................
Crankshaft Front Seal - Remove ...........................
Crankshaft Main Bearings - Install.........................
Crankshaft Main Bearings - Remove.....................
Crankshaft Pulley - Remove and Install ................
Crankshaft Rear Seal - Install................................
Crankshaft Rear Seal - Remove............................
Cylinder Head - Install ...........................................
Cylinder Head - Remove .......................................
80
80
78
78
43
43
43
43
77
77
76
76
42
42
42
37
37
37
37
61
61
60
60
D
Disassembly and Assembly Section........................ 4
E
Electric Starting Motor - Remove and Install ....... 101
Installation Procedure ...................................... 102
Removal Procedure ......................................... 101
Engine Oil Cooler - Remove and Install ................ 23
Engine Oil Line - Remove and Install .................... 21
Engine Oil Pan - Remove and Install..................... 67
Engine Oil Pressure Switch - Remove and Install.. 84
Engine Oil Pump - Install ....................................... 26
Engine Oil Pump - Remove ................................... 24
Engine Oil Relief Valve - Remove and Install ........ 24
Exhaust Manifold - Remove and Install ................. 15
104
Index Section
F
Fan - Remove and Install ...................................... 87
403C-11, 403C-15, 403C-17 and 404C-15
Engines) ........................................................... 91
Installation Procedure (404C-22 and 404C-22T
Engines) ........................................................... 90
403C-15, 403C-17 and 404C-15 Engines)....... 88
Removal Procedure (404C-22 and 404C-22T
Engines) ........................................................... 87
Flywheel - Install.................................................... 36
Flywheel - Remove................................................ 35
Flywheel Housing - Remove and Install ................ 39
Installation Procedure (Engines with Flywheel
Housing and Back plate) .................................. 40
Installation Procedure (Engines with Flywheel
Housing)........................................................... 41
Removal Procedure (Engines with Flywheel
Housing and Back plate) .................................. 39
Removal Procedure (Engines with Flywheel
Housing)........................................................... 40
Fuel Filter Base - Install........................................... 6
Installation Procedure .......................................... 6
Fuel Filter Base - Remove....................................... 5
Removal Procedure ............................................. 5
Fuel Injection Lines - Remove and Install................ 7
Fuel Injection Pump - Install ................................... 11
Installation Procedure ......................................... 11
Fuel Injection Pump - Remove .............................. 10
Fuel Injector - Install .............................................. 12
Fuel Injector - Remove .......................................... 12
Fuel Priming Pump - Install ..................................... 4
Fuel Priming Pump - Remove ................................. 4
Fuel Shutoff Solenoid - Remove and Install ............ 9
G
Glow Plugs - Remove and Install .......................... 86
SENR9973-01
Housing (Front) - Disassemble..............................

Disassembly Procedure .....................................
Housing (Front) - Install .........................................
Housing (Front) - Remove .....................................
45
45
50
50
44
44
I
Important Safety Information ................................... 2
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 17
Inlet and Exhaust Valves - Remove and Install ..... 19
L
Lifter Group - Remove and Install.......................... 63
P
Pistons and Connecting Rods - Assemble ............
Assembly Procedure..........................................
Pistons and Connecting Rods - Disassemble .......
Disassembly Procedure .....................................
Pistons and Connecting Rods - Install...................
Pistons and Connecting Rods - Remove...............
71
71
69
69
73
73
68
68
R
Rocker Shaft - Assemble....................................... 57
Assembly Procedure (402C-05, 403C-07, 403C-11
and 404C-15 engines)...................................... 57
Assembly Procedure (403C-15, 403C-17, 404C-22
and 404C-22T engines) ................................... 58
Rocker Shaft - Disassemble .................................. 56
Disassembly Procedure (402C-05, 403C-07,
403C-11 and 404C-15 engines) ....................... 56
Disassembly Procedure (403C-15, 403C-17,
404C-22 and 404C-22T engines)..................... 56
Rocker Shaft and Pushrod - Install........................ 59
Rocker Shaft and Pushrod - Remove.................... 55
H
Housing (Front) - Assemble................................... 47
Assembly Procedure.......................................... 47
T
Table of Contents..................................................... 3
SENR9973-01
105
Index Section
Turbocharger - Remove and Install ....................... 13

Installation procedure......................................... 14
Removal procedure............................................ 13
V
V-Belts - Remove and Install .................................
Valve Mechanism Cover - Remove and Install......
86
87
86
54
54
54
W
Water Pump - Install .............................................. 30
Installation Procedure (402C-05 and 403C-07
Engines) ........................................................... 31
403C-17, 404C-15, 404C-22 and 404C-22T
Engines) ........................................................... 30
Water Pump - Remove .......................................... 28
Removal Procedure (402C-05 and 403C-07
Engines) ........................................................... 29
404C-15, 404C-22 and 404C-22T Engines) .... 28
Water Temperature Regulator - Remove and
Install ................................................................... 32
Installation Procedure (402C-05 and 403C-07
engines) ........................................................... 34
403C-17, 404C-15, 404C-22 and 404C-22T
engines) ........................................................... 34
Removal Procedure (402C-05 and 403C-07
engines) ........................................................... 32
404C-15, 404C-22 and 404C-22T engines)..... 33
Water Temperature Regulator Housing - Remove and
Install ................................................................... 31
106
Index Section
SENR9973-01
SENR9973-01
107
Index Section
2007 Perkins Engines Company Limited

All Rights Reserved
Printed in U. K.

Perkins Seria 400 C Typ H... MANUAL

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SENR9973-01

- Disassembly and Assembly

400C Industrial Engine

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Connecting Rod Bearings - Install ........................ 75

Disassembly and Assembly

2. Install suitable plugs into the fuel lines in order to

Fuel Priming Pump - Remove

Note: The fuel priming pump can be oriented in two

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

Note: In order to remove the fuel priming pump

Fuel Priming Pump - Install

1. Loosen the hose clamps and remove the two fuel

Fuel Filter Base - Remove

1. Clean the mating surfaces of the fuel priming

Note: Ensure that the camshaft lobe for the fuel

1. Disconnect the fuel lines (1) and (2). Inspect the

Note: Put identification marks on all the fuel lines for

Fuel Filter Base - Install

Contaminants may cause rapid wear and shortened

1. Align the fuel filter base (3) with the mounting

Fuel Injection Lines - Remove

404C-22 and 404C-22T engines

1. Disconnect the union nuts (1) for the fuel injection

Note: The installation procedure is similar for the

404C-22 and 404C-22T engines

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

404C-22 and 404C-22T engines

1. Remove the plastic plugs from the fuel injectors

For engines with a rigid fuel return line, install new

The nozzles will be damaged if the top of the injector

The 402C-05, 403C-07, 403C-11 and 404C-15

The engine will be damaged if a defective fuel injector

For engines with a flexible fuel return hose,

Fuel Shutoff Solenoid Remove and Install

404C-22 and 404C-22T engines

5. Remove the plastic plugs from the fuel injection

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

1. Disconnect electrical connections (3) to the fuel

Note: The removal procedure is similar for the two

1. Check the condition of O-ring (2). If the O-ring is

Fuel Injection Pump - Remove

Contaminants may cause rapid wear and shortened

1. Remove the setscrews (4) and the nuts (2) that

2. Carefully raise the fuel injection pump (1) from

Fuel Injection Pump - Install

2. Install the correct thickness and the correct

3. Position the fuel injection pump (1) close to the

Fuel Injector - Remove

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

Fuel Injector - Install

Turbocharger - Remove and

1. Clean the injector bore in the cylinder head.

2. Install new seat washers (3) into the injector bore

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

9. Remove the nuts (19) and the washers (18).

3. Remove the exhaust pipe (not shown) from the

6. Place a suitable container below the turbocharger

2. Ensure that all of the turbocharger inlet and outlet

3. If the studs (17) were previously removed, install

Exhaust Manifold - Remove