C27 and C32 Generator Sets Engines Disassembly and Assembly Workshop Manual

C27 and C32 Generator Sets Engines Disassembly and Assembly Workshop Manual

High resolution, searchable, printable PDF format  

Covers: C27 and C32 Generator Sets Engines  with serial numbers:

• DWB1-Up (Generator Set)
• SXC1-Up (Generator Set)
• MED1-Up (Power Module)
• WDR1-Up (Generator Set)

Pages: 108
Format: PDF
Compatibility: Windows/Mac/Tablet

Table of Contents :

Disassembly and Assembly Section
Engine – Remove …………………………………………… 4
Engine – Install ………………………………………………. 6
Fuel Priming Pump – Remove and Install ………….. 9
Fuel Filter Base – Remove …………………………….. 10
Fuel Filter Base – Install ………………………………… 10
Fuel Filter and Water Separator – Remove and
Install ………………………………………………………….. 11
Fuel Transfer Pump – Remove ………………………… 12
Fuel Transfer Pump – Install ……………………………. 12
Electronic Unit Injector – Remove ……………………. 13
Electronic Unit Injector – Install ……………………….. 14
Electronic Unit Injector Sleeve – Remove …………. 15
Electronic Unit Injector Sleeve – Install …………….. 16
Turbocharger – Remove …………………………………. 17
Turbocharger – Disassemble ………………………….. 17
Turbocharger – Assemble ……………………………… 18
Turbocharger – Install …………………………………….. 18
Exhaust Manifold – Remove and Install …………… 19
Inlet and Exhaust Valve Springs – Remove and
Install …………………………………………………………. 20
Inlet and Exhaust Valves – Remove and Install …. 22
Inlet and Exhaust Valve Guides – Remove and
Install …………………………………………………………. 23
Inlet and Exhaust Valve Seat Inserts – Remove and
Install …………………………………………………………. 24
Engine Oil Filter Base – Remove …………………….. 25
Engine Oil Filter Base – Disassemble ………………. 26
Engine Oil Filter Base – Assemble …………………… 26
Engine Oil Filter Base – Install ………………………… 27
Engine Oil Cooler – Remove …………………………… 27
Engine Oil Cooler – Install ………………………………. 28
Engine Oil Pump – Remove ……………………………. 28
Engine Oil Pump – Disassemble ……………………… 29
Engine Oil Pump – Assemble ………………………….. 29
Engine Oil Pump – Install ……………………………….. 30
Water Pump – Remove ………………………………….. 31
Water Pump – Disassemble …………………………… 31
Water Pump – Assemble ……………………………….. 32
Water Pump – Install ……………………………………… 33
Water Temperature Regulator Housing – Remove and
Install ………………………………………………………… 33
Cooling System Package (Radiator, Aftercooler, Fuel
Cooler) – Remove ………………………………………… 35
Cooling System Package (Radiator, Aftercooler, Fuel
Cooler) – Install ……………………………………………. 36
Aftercooler – Remove ……………………………………. 38
Aftercooler – Install ……………………………………….. 40
Radiator Core – Remove ……………………………….. 42
Radiator Core – Install …………………………………… 44
Engine Support (Front) – Remove and Install ……. 45
Gear Group (Rear) – Remove …………………………. 46
Gear Group (Rear) – Install …………………………….. 48
Flywheel – Remove and Install ……………………….. 49
Crankshaft Rear Seal – Remove ……………………… 50
Crankshaft Rear Seal – Install …………………………. 50
Flywheel Housing – Remove and Install ………….. 51
Vibration Damper and Pulley – Remove and Install
………………………………………………………………….. 53
Crankshaft Front Seal – Remove …………………….. 54
Crankshaft Front Seal – Install ………………………… 55
Gear Group (Front) – Remove ………………………… 55
Gear Group (Front) – Install ……………………………. 56
Housing (Front) – Remove ……………………………… 57
Housing (Front) – Install …………………………………. 58
Housing (Rear) – Remove ………………………………. 60
Housing (Rear) – Install ………………………………….. 60
Valve Mechanism Cover – Remove and Install ….. 62
Valve Mechanism Cover Base – Remove and
Install …………………………………………………………. 62
Rocker Arm and Shaft – Remove …………………….. 63
Rocker Arm – Disassemble …………………………….. 64
Rocker Arm – Assemble …………………………………. 64
Rocker Arm and Shaft – Install ………………………… 65
Cylinder Head – Remove ……………………………….. 66
Cylinder Head – Install …………………………………… 68
Camshaft – Remove ………………………………………. 71
Camshaft – Install ………………………………………….. 73
Camshaft Bearings – Remove …………………………. 76
Camshaft Bearings – Install …………………………….. 76
Engine Oil Pan – Remove and Install ………………. 78
Cylinder Liner – Remove ………………………………… 79
Cylinder Liner – Install ……………………………………. 79
Piston Cooling Jets – Remove and Install …………. 80
Pistons and Connecting Rods – Remove ………….. 81
Pistons and Connecting Rods – Disassemble ……. 82
Pistons and Connecting Rods – Assemble ……….. 82
Pistons and Connecting Rods – Install ……………… 83
Connecting Rod Bearings – Remove ……………….. 84
Connecting Rod Bearings – Install …………………… 85
Crankshaft Main Bearings – Remove ……………….. 86
Crankshaft Main Bearings – Install …………………… 87
Crankshaft – Remove …………………………………….. 88
Crankshaft – Install ………………………………………… 90
Bearing Clearance – Check …………………………….. 92
Atmospheric Pressure Sensor – Remove and
Install …………………………………………………………. 93
Camshaft Position Sensor – Remove and Install .. 93
Crankshaft Position Sensor – Remove and Install .. 94
Coolant Temperature Sensor – Remove and
Install …………………………………………………………. 95
Engine Oil Pressure Sensor – Remove and Install
………………………………………………………………….. 96
Fuel Pressure Sensor – Remove and Install ……… 97
Fuel Temperature Sensor – Remove and Install … 97
Turbocharger Outlet Pressure Sensor – Remove and
Install …………………………………………………………. 98
Inlet Air Temperature Sensor – Remove and
Install …………………………………………………………. 99
Belt Guard – Remove and Install ……………………… 99
Fan Guard – Remove and Install …………………… 100
Fan – Remove and Install …………………………….. 101
Fan Drive – Remove and Install ……………………. 102
Electronic Control Module – Remove and Install .. 103
Alternator – Remove and Install ……………………. 104
Electric Starting Motor – Remove and Install ….. 105
Index Section
Index …………………………………………………………. 106