PERKINS ENGINE 1204F Disassembly and Assembly

PERKINS ENGINE

1204F

Disassembly and Assembly

• Pages: 329
• Size: 4.21 MB
• Format: PDF (Adobe Reader)
• Language : English

Table of Contents

Disassembly and Assembly Section

Fuel Priming Pump - Remove and Install (Electric

Fuel Lift Pump (EFLP)) ........................................5

Flow Control Valve - Remove and Install ................6

Fuel Filter Base - Remove and Install (Single

Secondary Fuel Filter)..........................................9

Fuel Filter Base - Remove and Install (Twin

Secondary Fuel Filter)........................................13

Water Separator and Fuel Filter (Primary) - Remove

and Install .........................................................16

Fuel Manifold (Rail) - Remove and Install ..............19

Relief Valve (Fuel) - Remove and Install................21

Fuel Injection Lines - Remove .............................23

Fuel Injection Lines - Install .................................25

Exhaust Cooler (NRS) - Remove and Install (Twin

Turbochargers)..................................................27

Exhaust Cooler (NRS) - Remove and Install (Side

Mounted Turbocharger) .....................................31

Exhaust Cooler (NRS) - Remove and Install (Top

Mounted Turbocharger) .....................................34

Inlet Air Control - Remove (NRS Induction Mixer) ..38

Inlet Air Control - Install (NRS Induction Mixer) ......40

Fuel Injection Pump - Remove .............................43

Fuel Injection Pump - Install ................................45

Fuel Injection Pump Gear - Remove .....................47

Fuel Injection Pump Gear - Install.........................47

Electronic Unit Injector - Remove..........................48

Electronic Unit Injector - Install .............................51

Turbocharger - Remove (First Stage

Turbocharger) ...................................................54

Turbocharger - Remove (Second Stage

Turbocharger) ...................................................56

Turbocharger - Remove (Side Mounted

Turbochargers)..................................................58

Turbocharger - Remove (Top Mounted Turbocharger

) .......................................................................59

Turbocharger - Install (First Stage Turbocharger)...61

Turbocharger - Install (Top Mounted Turbocharger

) .......................................................................64

Turbocharger - Install (Second Stage

Turbocharger) ...................................................66

Turbocharger - Install (Side Mounted

Turbochargers)..................................................69

Wastegate Solenoid - Remove and Install .............71

Exhaust Back Pressure Valve - Remove and Install73

Exhaust Gas Valve (NRS) - Remove and Install.....75

Clean Emissions Module - Remove and Install ......85

Diesel Exhaust Fluid Lines - Remove and Install....87

Diesel Exhaust Fluid Pump - Remove and Install ...90

DEF Injector and Mounting - Remove and Install ...92

Diesel Exhaust Fluid Tank - Remove and Install.....95

Manifold (DEF Heater) - Remove and Install..........97

Manifold (DEF Heater) Sensor - Disassemble

(Temperature, Level, Quality DEF Manifold

Sensor)........................................................... 101

Manifold (DEF Heater) Sensor - Assemble

(Temperature, Level, Quality DEF Manifold

Sensor)........................................................... 102

Solenoid Valve (DEF Heater Coolant) - Remove and

Install ............................................................. 105

Flexible Exhaust Pipe - Remove and Install ......... 106

Exhaust Manifold - Remove and Install (Single

Turbocharger Exhaust Manifold) ....................... 110

Exhaust Manifold - Remove and Install (Twin

Turbochargers Exhaust manifold) ..................... 115

Exhaust Elbow - Remove and Install (Top Mounted

and Side Mounted Turbocharger Exhaust

Elbow) ............................................................ 118

Exhaust Elbow - Remove and Install .................. 119

Support and Mounting (CEM) - Remove and

Install ............................................................. 120

Inlet and Exhaust Valve Springs - Remove and

Install ............................................................. 122

Inlet and Exhaust Valves - Remove and Install..... 126

Engine Oil Filter Base - Remove and Install ........ 129

Engine Oil Cooler - Remove............................... 130

Engine Oil Cooler - Install .................................. 131

Engine Oil Pump - Remove................................ 132

Engine Oil Pump - Install.................................... 133

Water Pump - Remove ...................................... 135

Water Pump - Install .......................................... 136

Water Temperature Regulator - Remove and

Install ............................................................. 138

Flywheel - Remove............................................ 139

Flywheel - Install ............................................... 140

Crankshaft Rear Seal - Remove ......................... 141

Crankshaft Rear Seal - Install............................. 142

Flywheel Housing - Remove and Install (Standard

Housing)......................................................... 143

Flywheel Housing - Remove and Install (Wet Back

End Housing) .................................................. 146

Crankshaft Pulley - Remove and Install .............. 149

Crankshaft Front Seal - Remove and Install

(Crankshaft Front Seal for Heavy Duty Front

Cover) ............................................................ 150

Crankshaft Front Seal - Remove and Install......... 151

Front Cover - Remove and Install (Heavy Duty Front

Cover) ............................................................ 152

Front Cover - Remove and Install ....................... 154

Gear Group (Front) - Remove and Install (Heavy

Duty Gear Group (Front)) ................................. 155

Gear Group (Front) - Remove and Install ............ 164

Idler Gear - Remove .......................................... 169

Idler Gear - Install.............................................. 172

Housing (Front) - Remove (Heavy Duty Housing

(Front)) ........................................................... 175

Housing (Front) - Remove.................................. 177

Housing (Front) - Install (Heavy Duty Housing

(Front)) ........................................................... 179

Housing (Front) - Install ..................................... 182

Accessory Drive - Remove and Install (Accessory

Drive SAE "A") ................................................ 184

Accessory Drive - Remove and Install (Accessory

Drive SAE "B") ................................................ 186

Crankcase Breather - Remove ........................... 189

Crankcase Breather - Install............................... 191

Valve Mechanism Cover - Remove and Install ..... 193

Rocker Shaft and Pushrod - Remove.................. 195

Rocker Shaft - Disassemble .............................. 198

Rocker Shaft - Assemble .................................. 199

Rocker Shaft and Pushrod - Install...................... 200

Cylinder Head - Remove.................................... 204

Cylinder Head - Install ....................................... 208

Lifter Group - Remove and Install (Hydraulic Lifter

Group)............................................................ 212

UENR4491-07 3

Table of Contents

Camshaft - Remove and Install .......................... 214

Camshaft Gear - Remove and Install ................. 216

Camshaft Bearings - Remove and Install ............ 221

Engine Oil Pan - Remove and Install (Cast Iron Oil

Pan) ............................................................... 222

Engine Oil Pan - Remove and Install (Aluminum and

Pressed Steel Oil Pans) ................................... 226

Balancer - Remove............................................ 231

Balancer - Install ............................................... 233

Piston Cooling Jets - Remove and Install ............ 235

Pistons and Connecting Rods - Remove ............. 237

Pistons and Connecting Rods - Disassemble ...... 238

Pistons and Connecting Rods - Assemble........... 240

Pistons and Connecting Rods - Install................. 242

Connecting Rod Bearings - Remove (Connecting

Rods in Position) ............................................. 243

Connecting Rod Bearings - Install (Connecting Rods

in Position)...................................................... 245

Crankshaft Main Bearings - Remove and Install

(Crankshaft in Position).................................... 246

Crankshaft - Remove......................................... 251

Crankshaft - Install ............................................ 253

Crankshaft Timing Ring - Remove and Install ...... 257

Crankshaft Gear - Remove and Install ................ 258

Crankshaft Gear (Balancer Drive) - Remove and

Install ............................................................. 260

Bearing Clearance - Check ................................ 262

Refrigerant Compressor - Remove and Install .... 263

Nitrogen Oxide Sensor - Remove and Install

(Nitrogen Oxide Sensor Positioned in Original

Equipment Manufacture (OEM) Exhaust Tube

Assembly)....................................................... 266

Nitrogen Oxide Sensor - Remove and Install

(Nitrogen Oxide Sensor on Engine)................... 267

Atmospheric Pressure Sensor - Remove and

Install ............................................................. 269

Camshaft Position Sensor - Remove and Install .. 270

Crankshaft Position Sensor - Remove and Install. 271

Coolant Temperature Sensor - Remove and

Install ............................................................. 272

Engine Oil Pressure Sensor - Remove and

Install ............................................................. 273

Fuel Pressure Sensor - Remove and Install......... 274

Fuel Temperature Sensor - Remove and Install ... 275

Ammonia Sensor - Remove and Install (Ammonia

Sensor if Equipped) ......................................... 277

Soot Antenna - Remove and Install..................... 279

Temperature Sensor (Exhaust) - Remove and Install

(Selective Catalytic Reduction (SCR) Temperature

Sensor)........................................................... 280

Temperature Sensor (DPF) - Remove and Install . 281

Temperature Sensor (Catalyst Inlet) - Remove and

Install ............................................................. 282

Temperature Sensor (Cooled Exhaust Gas) -

Remove and Install.......................................... 283

Pressure Sensor (Cooled Exhaust Gas) - Remove

and Install (Differential Pressure Sensor and Inlet

Pressure Sensor) ............................................ 284

Boost Pressure Sensor - Remove and Install....... 287

Inlet Manifold Temperature Sensor - Remove and

Install ............................................................. 288

Glow Plugs - Remove and Install ....................... 289

Alternator Belt - Remove and Install ................... 290

Idler Pulley - Remove and Install (Flat Idler

Pulley) ............................................................ 292

Idler Pulley - Remove and Install (Grooved Idler

Pulley) ............................................................ 292

Belt Tensioner - Remove and Install.................... 293

Fan - Remove and Install .................................. 294

Fan Drive - Remove and Install .......................... 295

Electronic Control Module - Remove................... 296

Electronic Control Module - Install ...................... 300

Alternator - Remove .......................................... 304

Alternator - Install .............................................. 306

Electric Starting Motor - Remove and Install ....... 309

Air Compressor - Remove and Install (Single

Cylinder Air Compressor) ................................. 310

Air Compressor - Remove and Install (Twin Cylinder

Air Compressor) .............................................. 316

Index Section

Index................................................................ 324

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