Table of Contents Engine Tools Air Induction ................................................................................................................................................................... 3-3 Cooling System ............................................................................................................................................................ 3-19 Crankshaft, Main Bearings and Flywheel .............................................................................................................. 3-45 Cylinder Block and Liners ......................................................................................................................................... 3-78 Engine Tools Cylinder Head, Valves and Cam Followers ........................................................................................................... 3-104 Electrical and Ignition Tools ................................................................................................................................... 3-174 Lube System................................................................................................................................................................ 3-180 Engine Test Tools ....................................................................................................................................................... 3-185 Fuel System Test Tools ............................................................................................................................................. 3-207 Fuel System Repair and Adjust ............................................................................................................................... 3-248 Pistons, Rings and Connecting Rods ..................................................................................................................... 3-322 Camshaft and Timing Gear Tools ............................................................................................................................ 3-342 Starting Systems ........................................................................................................................................................ 3-359 Engine Lifting and Positioning ................................................................................................................................ 3-361 3600 Engine Tools ...................................................................................................................................................... 3-379 3-1 Table of Contents Engine Tools 3-2 Air Induction Air Induction FT1984 Pressurizing Group Reference Engine Tools 367-7435, 378-4525, 378-4526 Aftercooler Testing Plugs Part Number Description 378-4525 Aftercooler Testing Plug 378-4526 Aftercooler Testing Plug 367-7435 Aftercooler Testing Plug 2586345 321-6022 Pressurizer Assembly Essential Tool Model: 793F, 795F, and 797F Off-Highway Truck Warranty: Six Months • Used to seal air induction system to test for air leaks temporarily — replaces primary and secondary air filters • Used with shop air supply and dealer supplied 0 to 70 kPa (0 to 10 psi) pressure gauge • Requires one pressurizer tool for each air cleaner (797F Off-Highway Truck requires five tools) • Each tool features a quick-disconnect air fitting and a preset pressure relief valve • 9H-5548 O-ring Seal is serviced separately Part Number Description 321-6022 Pressurizer Assembly 3-3 Air Induction 2586364 152-2067 Differential Pressure Gauge Model: Multiple Engine Models Warranty: Six Months • Used to monitor aftercooler pressure drop in applications with crankcase fumes recirculation • Minimize risk of engine reliability problems • Helps eliminate premature plugging of aftercooler cores • Increase service life of air cleaner • Eliminates need for using two gauges • Installs easily across air side of aftercooler core • Measures differential pressure continuously, regardless of fluctuation in system pressure Engine Tools • For maximum accuracy, calibrate gauge in position used • Magnahelic gauge with high pressure option Accuracy ±2% of full scale Weight .51 kg (18 oz) Range 0 - 101 cm (0 - 40 in) of water Minor divisions 1.0 Temperature range (-6° to 60° C) 20° to 140° F Maximum pressure 551 kPa (80 psi) Part Number Description 152-2067 Differential Pressure Gauge 2641610 Turbocharging Reconditioning Tools Model: Multiple Engine Models Warranty: Six Months The tools needed to service a particular turbocharger can be determined from the following charts. Reference SMHS6854, Special Instruction Part No. Description 3LK 4, 4A, 4C 4B, 4D V4HD, V4MD 4MD, 4ME 4HD F, E FT0165¹ Fixture X X X X X X X (Modified) FT0165 Fixture X X X X X X FT0168 Adapter X X FT0170 Support X X X X X Screw FT0174 Driver Tool X X X X X FT0175 Expander X X X X X Sleeve FT0623 Removal Tool X X FT0626 Spacer X X X X X Block FT0745 Pliers, Modi- X X X X X X fied FT0808 Adapter X X X ¹ FT0165 (Modified) replaces FT0165 Turbo Fixture V4HD Part Number Description 3LK 4 4A 4C 4B 4D V4MD 4MD 4ME 4HD F E 9S-6343 Cartridge Fixture 1 -- -- -- -- X X X 9S-6363 Fixture Group 2 -- -- -- -- X X X (Continued) 3-4 Air Induction 2641610 Turbocharging Reconditioning Tools (Continued) Model: Multiple Engine Models Warranty: Six Months 1 9S-6343 replaced FT0622 2 9S-6363 replaced FT0621 2641571 Manufacturer: AiResearch Part No. Descrip- T6 T12 T114 T18 T24 T3019 T04 TV81 TW81 tion Engine Tools FT0165¹ Fixture XXXXXXXXX (Modified) FT0165 Fixture X X X X X X FT0168 Adapter X X FT0170 Support X X X X X Screw FT0174 Driver X X X X X X X X Tool FT0745 Pliers, X X X X X X Modified FT0808 Adapter X FT1354 Adapter X X 9S-6363 Fixture X X X Group 9S-6343 Cartridge X X X Fixture ¹ FT0165 (Modified) replaces FT0165 Turbo Fixture 2896431 FT3191 Driver Socket Model: 770/772, D8 and 374/390 Warranty: None Specifications Length 84.14 mm (3.31 in) 2641333 9S-6343 Fixture Assembly and Turbine Holders • Used to disassemble turbocharger rotating assemblies by positioning turbine wheel in 9S-6343 Fixture Assembly for removal of shaft nut • Contains sockets required to hold Schwitzer turbine wheels • Set of 4 turbine holders available to hold AiResearch turbine wheels • Frame of fixture retains holder in place Item Description 2 Turbine Holders (not serviced) Item Part Number Description 1 9S-6343 Fixture Assembly 1 1 9S-6343 replaces FT0622 3-5 Air Induction 2696371 370-4653 C7.1 Turbocharger Alignment Tool Model Usage: Perkins C7.1 Engines Warranty: 6 Months • Used to counterbalance the turbocharger for easier installation and alignment • Used in assembly and removal of Turbocharger • Material: Steel Part Number Description Size Weight 370-4653 C7.1 Turbocharger Counter balance: 80 mm 3.13 kg (6.9 lbs.) Alignment Tool dia. x 175 mm long 2641411 9S-6363 Turbocharger Fixture Group Engine Tools • Used for disassembly and assembly Part Number Description of current and non-current turbo- 9S-6363 Turbocharger chargers Fixture Group 1 • Mounting plate tilts 90° so turbo- chargers can be positioned verti- cally or horizontally • In either position, mounting plate can be rotated to 8 fixed positions in 360° 1 9S-6363 replaces FT0621 2641483 FT0175 Ring Expander Sleeve • Used to service turbocharger (see chart) 2641668 FT0170 Support Screw • Used to service turbocharger (see chart) 3-6 Air Induction 2641740 FT0165 Modified Fixture • Existing FT0165 Fixture can be modified according to boxed dimensions so that only one adapter is needed for disassembly and assembly of all turbochargers • Material: SAE 1020 steel Engine Tools 2642172 FT0168 Fixture Adapter • Used to service turbocharger (see chart) • Material: SAE 1020 steel 2642100 FT0174 Driver Tool • Used to service turbocharger (see chart) • Material: SAE 4140 steel 2642028 FT0808 Fixture Adapter • Used to service turbocharger (see chart) • Material: SAE 1018 steel 3-7 Air Induction 2641956 FT1354 Turbocharger Fixture Adapter • Used with FT0165 Fixture for disassembly of AiResearch TV81 and TW81 Turbo- chargers • Material: SAE 1020 steel 2641884 Engine Tools FT0626 Spacer Block • Used to service turbocharger (see chart) • Material: SAE 1020 steel 2641812 FT0623 Insert Removal Tool • Used to service turbocharger (see chart) • Material: mild steel (bar) brass or aluminum (bearing plate) 2586455 1U-5429 Snap Ring Pliers Model: Multiple Engine Models Warranty: Six Months • Used to remove snap rings from Part Number Description deep bores in turbocharger hous- 1U-5429 Snap Ring Pliers ings and other components • Plier tips slightly off center to im- prove visibility • Pins made from 1.04 mm (0.041 in) diameter piano wire 3-8 Air Induction 2586472 304-9575 Bellows Tool Assembly Essential Tool C175-16 Generator Set Engine Warranty: Six Months • Used to remove and install turbocharger exhaust bellows • Fits over bellows to maintain proper shape and help prevent deforming of inlet and outlet • Covers and protects bellows during disassembly and assembly Engine Tools • Two-piece design with hinge and latch allow quick installation and removal • 306-7948 Inner Ring Segments (four per tool) and 2N-2658 Socket Head Screw (16 per tool) are serviced separately • Service/Repair Part: 306-7648 Ring Reference RENR7466, Service Manual, C175-16 Generator Set Engine, Disassembly and Assem- bly Part Number Description 304-9575 Bellows Tool Assembly 2586492 304-9576 Feeler Gauge Assembly Essential Tool Model: C175-16 Generator Set Engine Warranty: Six Months • Used to ensure corrugations in exhaust manifold bellows are properly aligned