PERKINS ENGINE 1204E Disassembly and Assembly

PERKINS ENGINE

1204E

Disassembly and Assembly

• Pages: 265
• Size: 5.15 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 ............... 7

Fuel Filter Base - Remove and Install (Twin

Secondary Fuel Filter) ......................................... 10

Fuel Filter Base - Remove and Install (Single

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

Water Separator and Fuel Filter (Primary) - Remove

and Install ............................................................ 17

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

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

Fuel Injection Lines - Remove ............................. 22

Fuel Injection Lines - Install ................................. 24

Exhaust Cooler (NRS) - Remove and Install (Top

mounted Turbocharger) ...................................... 27

Exhaust Cooler (NRS) - Remove and Install (Side

mounted Turbocharger) ...................................... 30

Exhaust Cooler (NRS) - Remove and Install (Twin

Turbocharger) ..................................................... 33

Inlet Air Control - Remove (NRS Induction Mixer) .. 37

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

Fuel Injection Pump - Remove ............................ 41

Fuel Injection Pump - Install ................................ 43

Fuel Injection Pump Gear - Remove .................... 45

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

Electronic Unit Injector - Remove ......................... 46

Electronic Unit Injector - Install ............................. 49

Turbocharger - Remove (First Stage

Turbocharger) ..................................................... 51

Turbocharger - Remove (Top Mounted Turbocharger

) ........................................................................... 53

Turbocharger - Remove (Side Mounted

Turbochargers) .................................................... 55

Turbocharger - Remove (Second Stage

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

Turbocharger - Install (First Stage Turbocharger) .. 57

Turbocharger - Install (Top Mounted Turbocharger

) ........................................................................... 60

Turbocharger - Install (Side Mounted

Turbochargers) .................................................... 62

Turbocharger - Install (Second Stage

Turbocharger) ..................................................... 63

Wastegate Solenoid - Remove and Install ............ 66

Exhaust Back Pressure Valve - Remove and

Install ................................................................... 68

Flexible Exhaust Pipe - Remove and Install ......... 70

Exhaust Manifold - Remove and Install (Twin

Turbocharger Exhaust manifold) ......................... 73

Exhaust Manifold - Remove and Install (Single

Turbocharger Exhaust Manifold) ......................... 76

Exhaust Elbow - Remove and Install ................... 80

Exhaust Elbow - Remove and Install (Top Mounted

and Side Mounted Turbocharger Exhaust

Elbow) ................................................................. 81

Diesel Particulate Filter - Remove ........................ 82

Diesel Particulate Filter - Install ............................ 85

Inlet and Exhaust Valve Springs - Remove and

Install ................................................................... 88

Inlet and Exhaust Valves - Remove and Install .... 91

Engine Oil Filter Base - Remove and Install ........ 94

Engine Oil Cooler - Remove ................................. 95

Engine Oil Cooler - Install ..................................... 96

Engine Oil Pump - Remove .................................. 97

Engine Oil Pump - Install ...................................... 98

Water Pump - Remove ......................................... 99

Water Pump - Install ........................................... 100

Water Temperature Regulator - Remove and Install

........................................................................... 102

Flywheel - Remove ............................................. 103

Flywheel - Install ................................................. 104

Crankshaft Rear Seal - Remove ......................... 105

Crankshaft Rear Seal - Install ............................. 106

Flywheel Housing - Remove and Install (Wet Back

End Housing) .................................................... 107

Flywheel Housing - Remove and Install (Standard

Housing) ............................................................. 110

Crankshaft Pulley - Remove and Install .............. 112

Crankshaft Front Seal - Remove and Install ........ 113

Crankshaft Front Seal - Remove and Install

(Crankshaft Front Seal for Heavy Duty Front

Cover) ................................................................ 115

Front Cover - Remove and Install ........................ 116

Front Cover - Remove and Install (Heavy Duty Front

Cover) ................................................................ 117

Gear Group (Front) - Remove and Install ............ 118

Gear Group (Front) - Remove and Install (Heavy

Duty Gear Group (Front)) .................................. 124

Idler Gear - Remove ........................................... 131

Idler Gear - Install ............................................... 133

Housing (Front) - Remove .................................. 135

Housing (Front) - Remove (Heavy Duty Housing

(Front)) .............................................................. 137

Housing (Front) - Install ...................................... 138

Housing (Front) - Install (Heavy Duty Housing

(Front)) .............................................................. 141

Accessory Drive - Remove and Install (Accessory

Drive SAE "B") .................................................. 143

Accessory Drive - Remove and Install (Accessory

Drive SAE "A") .................................................. 146

Crankcase Breather - Remove ........................... 148

Crankcase Breather - Install ............................... 149

Valve Mechanism Cover - Remove and Install ... 151

Rocker Shaft and Pushrod - Remove ................. 153

Rocker Shaft - Disassemble .............................. 155

Rocker Shaft - Assemble ................................... 156

Rocker Shaft and Pushrod - Install ..................... 157

Cylinder Head - Remove .................................... 161

Cylinder Head - Install ........................................ 164

Lifter Group - Remove and Install (Hydraulic Lifter

Group) ............................................................... 168

Camshaft - Remove and Install ......................... 169

Camshaft Gear - Remove and Install ................ 172

Camshaft Bearings - Remove and Install .......... 176

Engine Oil Pan - Remove and Install (Aluminum and

Pressed Steel Oil Pans) .................................... 177

Engine Oil Pan - Remove and Install (Cast Iron Oil

Pan) .................................................................. 181

Balancer - Remove ............................................. 184

Balancer - Install ................................................. 185

Piston Cooling Jets - Remove and Install ........... 188

Pistons and Connecting Rods - Remove ............ 189

Pistons and Connecting Rods - Disassemble ..... 190

Pistons and Connecting Rods - Assemble ......... 192

Pistons and Connecting Rods - Install ................ 193

Connecting Rod Bearings - Remove (Connecting

Rods in Position) ............................................... 195

Connecting Rod Bearings - Install (Connecting Rods

in Position) ........................................................ 196

Crankshaft Main Bearings - Remove and Install

(Crankshaft in Position) ..................................... 197

Crankshaft - Remove .......................................... 201

Crankshaft - Install .............................................. 204

Crankshaft Timing Ring - Remove and Install .... 207

Crankshaft Gear - Remove and Install .............. 208

Crankshaft Gear (Balancer Drive) - Remove and

Install ................................................................. 209

Bearing Clearance - Check ................................. 210

Refrigerant Compressor - Remove and Install ... 211

Atmospheric Pressure Sensor - Remove and

Install ................................................................. 214

Camshaft Position Sensor - Remove and Install .. 215

Crankshaft Position Sensor - Remove and

Install ................................................................. 216

Coolant Temperature Sensor - Remove and

Install ................................................................. 217

Engine Oil Pressure Sensor - Remove and Install

........................................................................... 218

Fuel Temperature Sensor - Remove and Install .. 219

Soot Antenna - Remove and Install .................... 221

Temperature Sensor (DPF) - Remove and

Install ................................................................. 222

Temperature Sensor (Cooled Exhaust Gas) - Remove

and Install .......................................................... 223

Pressure Sensor (Cooled Exhaust Gas) - Remove

and Install (NRS Inlet and Outlet Pressure

Sensors) ............................................................ 224

Boost Pressure Sensor - Remove and Install ..... 226

Inlet Manifold Temperature Sensor - Remove and

Install ................................................................. 227

Glow Plugs - Remove and Install ....................... 228

Alternator Belt - Remove and Install .................. 229

Idler Pulley - Remove and Install (Grooved Idler

Pulley) ............................................................... 231

Idler Pulley - Remove and Install (Flat Idler

Pulley) ............................................................... 231

Belt Tensioner - Remove and Install ................... 232

Fan - Remove and Install ................................... 233

Fan Drive - Remove and Install ......................... 234

Electronic Control Module - Remove .................. 235

Electronic Control Module - Install ...................... 239

Alternator - Remove ............................................ 242

Electric Starting Motor - Remove and Install ..... 245

Alternator - Install ................................................ 246

Air Compressor - Remove and Install (Twin Cylinder

Compressor) ..................................................... 249

Air Compressor - Remove and Install (Single

Cylinder) ............................................................ 255

Index Section

Index ................................................................... 261

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