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Engine Design Type 1 Engines and 9RM Engines: Ver Imagen
Engine Design Type 1 Engines and 9RM Engines: Ver Imagen
Illustration 1
g00296342
Cylinder and valve location for Type 1 engines and 9RM engines
(A) Exhaust valves
(B) Inlet valves
Note: Type 1 engines can be identified in two ways. The first method refers to
Illustration 1. When the valve cover is removed, look at the cylinder head valves. Type
1 engines have two exhaust valves in a row and two inlet valves that are in a row.
The second method does not require the removal of the valve cover. Refer to the inlet
manifold and the exhaust manifold. Type 1 engines have two exhaust ports in a row and
two inlet ports that are in a row.
Type ... Four cylinder and four stroke
Combustion system ... Direct injection
Nominal Bore ... 100 mm (3.937 inch)
Stroke ... 127 mm (5.00 inch)
Capacity ... 4 liters (243 in3)
Compression Ratio ... 16:1
Number of cylinders ... 4
Arrangement of cylinders ... in-line
Firing Order ... 1, 3, 4, 2
Valve Lash
Inlet valve ... 0.20 mm (.008 inch)
Exhaust valve ... 0.45 mm (.018 inch)
When the crankshaft is viewed from the front of the engine the crankshaft rotates in the
following direction: ... Clockwise
When the camshaft is viewed from the front of the engine the camshaft rotates in the
following direction: ... Clockwise
Note: The front end of the engine is opposite the flywheel end. The left side and the
right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the
front cylinder.
Illustration 2
g00296424
Cylinder and valve location for Type 2 engines and 7BJ engines
(A) Exhaust valves
(B) Inlet valves
Note: Type 2 engines can be identified in two ways. The first method refers to
Illustration 2. When the valve cover is removed, look at the cylinder head valves. Type
2 engines alternate the exhaust valves and the inlet valves.
Note: Some of the Type 2 7BJ engines may look like the Type 1 engines. When the
valve cover is removed, these engines may have two exhaust valves in a row and two
inlet valves in a row. This is only a small percentage of the Type 2 7BJ engines.
The second method does not require the removal of the valve cover. Refer to the inlet
manifold and the exhaust manifold. Type 2 engines alternate the exhaust ports and the
inlet ports.
Type ... Four cylinder and four stroke
Combustion system ... Direct injection
Nominal Bore ... 100 mm (3.937 inch)
Stroke ... 127 mm (5.00 inch)
Capacity ... 4 liters (243 in3)
Compression Ratio ... 17.25:1
Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, or
Stanadyne fuel injection pumps may be equipped to the engine.
Bosch Fuel Injection Pump (EPVE)
Ver imagen
Illustration 1
g00896561
Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Bosch dealer. Please consult your parts book for availability of parts on the
outside of the pump that are not related to the settings of the fuel pump and for the
possibility of remanufacturing options.
Hub nut (not shown)
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(1) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 Nm (35 to 40 lb in)
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 Nm (44 to 53 lb in)
(3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm
(16 lb ft)
(4) Boost control (if equipped)
(5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
Nm (35 to 40 lb in)
(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ...
22 Nm (16 lb ft)
(7) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 Nm (52 to 60 lb ft)
Ver imagen
Illustration 2
g00766439
g00639086
Illustration 3
Note: Before the crankshaft is turned or the fuel injection pump is installed, move the
locking spacer (9) under the locking screw (10). Refer to position (A) that is in
Illustration 3. This position ensures that the pump drive shaft is released.
Timing Information for the Bosch Fuel Injection Pump
Table 1
Early Bosch Fuel Injection Pump Without Locking Screw
Static
Timing
Position
Before TC
Position
(degrees)
Piston
Displacemen
t (1)
Fuel
Injection
Pump Mark
Angle
(degrees) (1)
"BK"
308
314
12
1.78 mm
(0.070 inch)
"CK"
308
314
12
1.78 mm
(0.070 inch)
Code
Letters on
Fuel
Injection
Pump
Engine
Check
Angle
(degrees)
(1
"DK"
306
313
14
2.42 mm
(0.095 inch)
"EK"
308.5
315.5
14
2.42 mm
(0.095 inch)
306.5
315.5
18
3.99 mm
(0.157 inch)
"EM"
288.5
295.5
14
2.42 mm
(0.095 inch)
"FM"
289
295
12.5
1.93 mm
(0.076 inch)
"JM"
"EK"
(2)
"JM"
(3)
"JM"
(4)
TDC
"KC"
(5)
TDC
"KL"
(5)
TDC
TDC
"PM"
12
"SK"
TDC
"ML"
"TL"
(5)
(5)
VM
2 ATDC
(1)
The engine must be set at the TC position on the compression stroke for the
number 1 piston. The fuel injection pump mark angle and the displacement of
the piston can be checked when the plunger for the fuel injection pump is set at
1.00 mm (0.039 inch).
(2)
(3)
(4)
"AD80643" only
(5)
The cold start advance (KSB) must be energized before the timing is set.
Note: Later Bosch Fuel Injection Pumps use a pin to time the pump.
Stanadyne Fuel Injection Pump (DB2 or DB4)
Ver imagen
Illustration 4
g00788020
Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Stanadyne dealer. Please consult your parts book for availability of parts on
the outside of the pump that are not related to the settings of the fuel pump and for the
possibility of remanufacturing options.
Hub nut (not shown)
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(1) Electrical connection for the stop solenoid
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 Nm (44 to 53 lb in)
(3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
Nm (35 to 40 lb in)
(4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 Nm (35 to 40 lb in)
(5) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(6) Adjustment screw for advance timing
(7) Tighten the fittings for the fuel discharge to the following torque. ... 70.5 to 81.4
Nm (52 to 60 lb ft)
(8) Tighten the nuts for the high pressure fuel injection line to the following torque. ...
22 Nm (16 lb ft)
(9) Tighten the nut for the end cap to the following torque. ... 22 Nm (16 lb ft)
NOTICE
The No. 1 cylinder must be at the top center position on the
compression stroke before the fuel injection pump is installed. If the
crankshaft needs to be rotated, the fuel injection pump must be
mounted temporarily or the loose gear could cause damage to the front
housing.
Engine Check
Angle (degrees)
282
291
"AL"
326
336
"BL"
326
336
"CL"
327
333
247.5
"DL"
332
338
"FL"
326
333
"GL"
326
332
"HC"
282
290.5
"JL"
325
334.5
"KM"
282
290
"LM"
282
287
288.5
295
282
287
288.5
295
"NC"
282
294
"SL"
331.5
338
"SM"
282
291
"TC"
282
290
"TM"
282
290.5
"CL"
(1)
"LM"
(2)
"MM"
"MM"
(3)
"UC"
228.5
296
"VL"
326
389
"XK"
325
331.5
"YK"
325
334.5
"YL"
330
338
"ZK"
326
334
"ZM"
(4)
282
287
"ZM"
(5)
282
289
(1)
(2)
(3)
(4)
The values are for the fuel injection pumps with a serial number up to
"7665964".
(5)
The values are for the fuel injection pump with a serial number that includes
"7665965". The values are also for the fuel injection pumps with serial numbers
that are higher than "7665965".
Ver imagen
Illustration 5
g00788005
Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Delphi dealer. Please consult your parts book for availability of parts on the
outside of the pump that are not related to the settings of the fuel pump and for the
possibility of remanufacturing options.
(1) Hub nut
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(2) O-ring
(3) Locking spacer
The drive shaft of the fuel injection pump must not be turned without the spacer in
position under the locking screw (4) .
(4) Tighten the locking screw to the following torque. ... 10 Nm (7 lb ft)
The locking screw prevents the rotation of the drive shaft.
Ver imagen
g00292837
Illustration 6
Before the crankshaft is turned or the fuel injection pump is installed, move the locking
spacer (3) under the locking screw (4). Refer to position (A) that is in Illustration 6. This
position ensures that the pump drive shaft is released.
(5) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 Nm (44 to 53 lb in)
(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 Nm
(35 to 40 lb in)
(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 Nm
(35 to 40 lb in)
(8) Electrical connection for the stop solenoid
(9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm
(16 lb ft)
(10) Tighten the nuts for the fuel line to the following torque. ... 22 Nm (16 lb ft)
(11) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(12) Electrical connection for cold starting aid
(13) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 Nm (52 to 60 lb ft)
Timing Information for the Delphi Fuel Injection Pump
Table 3
Engine Check
Angle (degrees)
"AK"
325.5
336
"AM"
282
290.5
"BF"
326
334
"BM"
281
291
"CM"
282.5
291.5
"DM"
282.25
290.5
"FK"
325.5
336
"GK"
325
336
"GM"
282
290.5
"HK"
326
336
"HM"
282
291
"JK"
325
334
"KK"
325
334
"LK"
327
337.5
328
337.5
326
336
325
336
326
334
"LK"
(1)
"MK"
"MK"
"PK"
(2)
"RK"
328
336
"RM"
282.5
290.5
"TK"
327
334
"UK"
326
334
"XM"
282
291
(1)
"YA31257" only
(2)
"YA50532" only
Table 4
Dephi Fuel Injection Pump With Locking Screw
Code Letters on Fuel Injection Pump
"BC"
336.5
"CC"
338.5
"DC"
337.5
"EC"
337.5
"FC"
335.5
"GC"
337
"PC"
339
"RC"
339
"SC"
341
"XL"
22
Note: Later Delphi Fuel Injection Pumps are timed with a pin.
1
Illustration 1
g00308903
(1) Tighten the union nut of the high pressure fuel line (not shown) to the following
torque: ... 18 Nm (13.3 lb ft)
(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ...
9.5 Nm (84 lb in)
(3) Tighten the flange bolts (not shown) for the clamp to the following torque: ... 12
Nm (9 lb ft)
Note: Remove the original seat washer from the threaded hole for the fuel injection
nozzle which is located in the cylinder head. If the original seat washer is not removed,
the projection of the nozzle will be incorrect when a new seat washer is installed. Do
not reuse the seal (4) and the seat washer (7) .
Bench test the fuel injection nozzles at a temperature of 18 to 20 C (64 to 70 F).
Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil is
available in 5 gallon containers ( 6V-6068 Calibration Fluid ) and 55 gallon containers (
6V-6067 Calibration Fluid ). If dirty oil is used for the test, the components of the fuel
injection nozzle will be damaged.
Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and
Seat Test".
Table 1
Pressure Settings for the Fuel Injection Nozzles for the Type 1 Engines and 9RM
Engines
Code (1)
Pressure Setting
"HU"
22291 kPa (3233 psi)
"HV"
25331 kPa (3674 psi)
"HZ"
22291 kPa (3233 psi)
"JA"
25331 kPa (3674 psi)
"JB"
25331 kPa (3674 psi)
"JE"
22291 kPa (3233 psi)
"JF"
25331 kPa (3674 psi)
"JG"
23304 kPa (3380 psi)
"JH"
25331 kPa (3674 psi)
"JJ"
25331 kPa (3674 psi)
"JK"
22291 kPa (3233 psi)
"JL"
25331 kPa (3674 psi)
"JR"
25331 kPa (3674 psi)
"JS"
25331 kPa (3674 psi)
"JT"
25331 kPa (3674 psi)
"JU"
22291 kPa (3233 psi)
"JY"
25331 kPa (3674 psi)
"NJ"
22291 kPa (3233 psi)
"NK"
22801 kPa (3307 psi)
"NL"
22801 kPa (3307 psi)
"NM"
23304 kPa (3380 psi)
"NN"
23304 kPa (3380 psi)
"NP"
22291 kPa (3233 psi)
"NR"
23304 kPa (3380 psi)
"NS"
25331 kPa (3674 psi)
"NT"
23304 kPa (3380 psi)
"NU"
22291 kPa (3233 psi)
"NV"
22291 kPa (3233 psi)
"NW"
22291 kPa (3233 psi)
"RD"
"RE"
"RF"
"RH"
"RK"
"RM"
"RN"
"RP"
"RR"
"RS"
"RT"
"RU"
"RV"
(1)
The code letters are stamped on the side of the fuel injector body. The code letters are located below
the connection for the nut of the high pressure fuel line.
Note: Ensure that the new fuel injection nozzles have the same identification code as
the nozzles which were originally installed in the cylinder head.
Leakage in 10 seconds ... 0 drops
Illustration 2
g00293085
(1) Tighten the union nut of the high pressure fuel line (not shown) to the following
torque: ... 22 Nm (16 lb ft)
(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ...
9.5 Nm (84 lb in)
(3) Tighten the nut of the fuel injection nozzle to the following torque: ... 30 Nm (22 lb
ft)
Note: When the fuel injection nozzle is installed, put a 2.0 mm (.08 inch) bead of 4C5591 Anti-Seize Compound on the first two threads of the gland nut. Do not rotate the
fuel injection nozzle after installation. The seal which is made by the anti-seize
compound may break. A broken seal may allow leakage past the seat of the fuel
injection nozzle.
(4) Wire clip
(5) Seat washer
Note: Remove the original seat washer from the threaded hole for the fuel injection
nozzle which is located in the cylinder head. If the original seat washer is not removed,
the projection of the nozzle will be incorrect when a new seat washer is installed. Do
not reuse the seat washer (5) .
Bench test the fuel injection nozzles at a temperature of 18 to 20 C (64 to 70 F).
Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil is
available in 5 gallon containers ( 6V-6068 Calibration Fluid ) and 55 gallon containers (
6V-6067 Calibration Fluid ). If dirty oil is used for the test, the components of the fuel
injection nozzle will be damaged.
Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and
Seat Test".
Table 2
Pressure Settings for the Fuel Injection Nozzles for the Type 2 Engines and 7BJ
Engines
Code (1)
Pressure Setting
"KB"
30406 kPa (4410 psi)
"KC"
28979 kPa (4203 psi)
"KD"
29385 kPa (4262 psi)
"KE"
29385 kPa (4262 psi)
"KF"
29385 kPa (4262 psi)
"KG"
29385 kPa (4262 psi)
"KH"
29392 kPa (4263 psi)
"KJ"
25338 kPa (3675 psi)
"KK"
30406 kPa (4410 psi)
"KL"
"NX"
29385 kPa (4262 psi)
"NY"
29392 kPa (4263 psi)
"NZ"
29392 kPa (4263 psi)
"PA"
29392 kPa (4263 psi)
"PB"
29392 kPa (4263 psi)
"PC"
"PD"
"PE"
"RZ"
The code letters are stamped on the side of the fuel injector body. The code letters are located below
the connection for the nut of the high pressure fuel line.
Note: Ensure that the new fuel injection nozzles have the same identification code as
the nozzles which were originally installed in the cylinder head.
Leakage in 10 seconds ... 0 drops
1
Ver imagen
Illustration 1
g00293216
Rocker Shaft
SMCS - 1102
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
Illustration 1
g00876530
Outside diameter of the rocker arm bushing ... 22.28 to 22.31 mm (0.8770 to
0.8785 inch)
Inside diameter of the rocker arm bushing ... 19.06 to 19.10 mm (0.7505 to
0.7520 inch)
Clearance between the rocker arm bushing and the rocker shaft ... 0.03 to 0.09
mm (0.001 to 0.0035 inch)
Maximum permissible clearance between the rocker arm bushing and the rocker
shaft ... 0.13 mm (0.005 inch)
(3) Tighten the bolts evenly. Begin in the center and work toward the outside. Tighten
the bolts to the following torque.
Cast iron or steel rocker shaft brackets ... 88 Nm (65 lb ft)
Aluminum rocker shaft brackets ... 40 Nm (30 lb ft)
(4) Diameter of the rocker shaft ... 19.01 to 19.04 mm (0.7485 to 0.7495 inch)
(5) Tighten the bolt to the following torque. ... 4 Nm (35 lb in)
1
1
Ver imagen
g00529181
Illustration 1
0
/sisw eb/sisw eb/m i01063749
Illustration 1
Inlet valves and exhaust valves
g00295326
Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.
The valve lash is the following value when the engine is hot or cold:
Inlet valves ... 0.20 mm (0.008 inch)
Exhaust valves ... 0.45 mm (0.018 inch)
Ver imagen
Illustration 2
g00295327
(11) Machine the recess in the head for valve seat inserts to the following dimensions:
Inlet
(A) ... 7.19 to 7.32 mm (0.283 to 0.288 inch)
(B) ... 51.220 to 51.240 mm (2.0167 to 2.0175 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Exhaust
(A) ... 9.52 to 9.65 mm (0.375 to 0.380 inch)
(B) ... 42.620 to 42.650 mm (1.6779 to 1.6790 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Note: When a new valve seat insert is installed, a new valve and valve guide must be
installed. Refer to the Disassembly and Assembly for removal and installation
procedures.
Ver imagen
Illustration 3
g00517019
Illustration 4
g00294082
cylinder head. Then, the guides and inserts are cut and reamed in one operation with
special tooling. This procedure ensures the concentricity of the valve seat to the valve
guide in order to create a seal that is tight. Refer to the Disassembly and Assembly
Manual for removal and installation procedures.
(4) Diameter of the exhaust valve stem ... 8.94 to 8.96 mm (0.352 to 0.353 inch)
Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.0026 to 0.0033 inch)
Maximum permissible clearance of valve in valve guide ... 0.104 mm (0.0041 inch)
Overall length of the exhaust valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(5) Diameter of the inlet valve stem ... 8.953 to 8.975 mm (0.3525 to 0.3533 inch)
Clearance of valve in the valve guide ... 0.025 to 0.069 mm (0.001 to 0.003 inch)
Maximum permissible clearance of valve in valve guide ... 0.089 mm (0.0035 inch)
Overall length of the inlet valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(6) Exhaust valve face angle ... 45 degrees
Valve seat angle ... 46 degrees
Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.
(7) Exhaust valve head diameter ... 40.88 to 41.12 mm (1.609 to 1.619 inch)
Valve depth below the cylinder head face
Minimum ... 1.50 mm (0.059 inch)
Maximum ... 1.80 mm (0.071 inch)
Service wear limit ... 2.05 mm (0.081 inch)
(8) Diameter of the inlet valve ... 42.88 to 43.12 mm (1.688 to 1.698 inch)
Valve depth below the cylinder head face
Minimum ... 1.40 mm (0.055 inch)
Maximum ... 1.70 mm (0.067 inch)
Service wear limit ... 1.95 mm (0.077 inch)
(9) Inlet valve face angle ... 45 degrees
Valve seat angle ... 46 degrees
Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.
The valve lash is the following value when the engine is hot or cold:
Inlet valves ... 0.20 mm (0.008 inch)
Exhaust valves ... 0.45 mm (0.018 inch)
Ver imagen
Illustration 5
g00295327
(11) Machine the recess in the head for valve seat inserts to the following dimensions.
Inlet
(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)
(B) ... 45.535 to 45.560 mm (1.7927 to 1.7937 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Exhaust
(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)
(B) ... 43.535 to 43.560 mm (1.7140 to 1.7150 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Note: When a new valve seat insert is installed, a new valve and valve guide must be
installed. Refer to Disassembly and Assembly for removal and installation procedures.
Ver imagen
g00517019
Illustration 6
Angles and dimensions of the valve seat insert
(12) Valve seat insert
(D) Included angle of the faces
(E) Dimension of chamfer
(F) Vertical angle of chamfer
Cylinder Head
SMCS - 1100
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Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
Illustration 1
g00295370
Use the following procedure in order to tighten the cylinder head bolts:
1. Put engine oil on the threads of the bolts and the nuts. Tighten bolts (1) through
bolts (22) in a numerical sequence in Illustration 1.
Torque for the bolts ... 110 Nm (81 lb ft)
2. Tighten bolts (1) through bolts (22) again in a numerical sequence.
Torque for bolts ... 110 Nm (81 lb ft)
3. Rotate bolts (1) through bolts (22) in a numerical sequence to the following
values:
a. Tighten the bolts of short length "S" to the following value.
Rotate the bolts in a clockwise direction: ... 150 degrees
a Tighten the bolts of medium length "M" to the following value.
Rotate the bolts in a clockwise direction: ... 180 degrees
a Tighten the bolts of long length "L" to the following value.
Rotate the bolts in a clockwise direction: ... 210 degrees
Ver imagen
Illustration 2
g00295371
(1) Tighten the nuts that hold fuel injectors to the following torque: ... 12 Nm (10 lb ft)
Note: When the fuel injection nozzle is removed, the following items must be replaced:
dust seal and seat washer.
(2) Tighten the nuts for fuel line to the following torque: ... 18 Nm (13 lb ft)
(3) Tighten the bolts that hold the rocker shaft to the cylinder head to the following
torque:
Begin tightening the inner bolts. Then tighten the bolts by working toward the end of
the shaft.
Cast iron or steel bracket ... 75 Nm (55 lb ft)
Aluminum bracket ... 40 Nm (30 lb ft)
(4) Valve lash
Inlet ... 0.20 mm (.008 inch)
Exhaust ... 0.45 mm (.018 inch)
(5) Maximum permissible nozzle projection below cylinder head face after
resurfacing ... 4.45 mm (.175 inch)
Maximum allowance for resurfacing ... 0.30 mm (.012 inch)
(6) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)
Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
Ver imagen
Illustration 3
g00295372
Positions for measuring the bow of the cylinder head (typical example)
Illustration 4
g00295370
Use the following procedure in order to tighten the cylinder head bolts:
1. Put engine oil on the threads of bolts. Tighten bolts (1) through bolts (22) in a
numerical sequence in Illustration 4.
Torque for bolts ... 110 Nm (81 lb ft)
2. Tighten bolts (1) through bolts (22) again in a numerical sequence.
Torque for bolts ... 110 Nm (81 lb ft)
3. Rotate bolts (1) through bolts (26) in a numerical sequence to the following
values:
a. Tighten the bolts of short length "S" to the following value.
Rotate the bolts in a clockwise direction: ... 150 degrees
a Tighten the bolts of medium length "M" to the following value.
Rotate the bolts in a clockwise direction: ... 180 degrees
a Tighten the bolts of long length "L" to the following value.
Rotate the bolts in a clockwise direction: ... 210 degrees
Ver imagen
Illustration 5
g00295373
Note: When the fuel injection nozzle is removed, the following items must be replaced:
dust seal and seat washer.
(1) Tighten the bolts that hold the rocker shaft to the cylinder head to the following
torques:
Begin tightening the inner bolts. Then tighten the bolts by working toward the end of
the shaft.
Cast iron or steel bracket ... 75 Nm (55 lb ft)
Aluminum bracket ... 40 Nm (30 lb ft)
(2) Valve lash
Inlet ... 0.20 mm (.008 inch)
Exhaust ... 0.45 mm (.018 inch)
(3) Maximum permissible nozzle projection below cylinder head face after
resurfacing ... 4.45 mm (.175 inch)
Maximum allowance for resurfacing ... 0.30 mm (.012 inch)
(4) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)
Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
Ver imagen
g00295372
Illustration 6
Positions for measuring the bow of the cylinder head (typical example)
Turbocharger
SMCS - 1052
/sisw eb/sisw eb/m /sisw eb/mediase
Turbocharger
Ver imagen
Illustration 1
g00295466
(1) Put oil on the threads of the nut and put oil on the seat face.
Tighten the impeller nut to the following torque: ... 2 to 2.3 Nm (18 to 20 lb in)
Tighten the nut again to the following value: ... 110 degrees
Note: Do not bend or add stress to the shaft when the nut is tightened.
(2) Tighten the bolts, which hold the back plate, to the following torque: ... 8.5 to 10.2
Nm (75 to 90 lb in)
(3) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
compressor housing to the center section, to the following torque: ... 15.3 to 18.7 Nm
(12 to 14 lb ft)
(4) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
turbine housing to the center section, to the following torque: ... 18.6 to 20.4 Nm (14 to
15 lb ft)
(5) Turbine wheel assembly
Minimum journal outside diameter ... 10.152 mm (.3997 inch)
Ring groove diameter (minimum) ... 14.401 mm (.5670 inch)
Ring groove width (maximum) ... 1.740 mm (.0685 inch)
Hub outside diameter (minimum) ... 17.323 mm (.6820 inch)
(6) End play for shaft
Minimum permissible end play ... .03 mm (.001 inch)
Maximum permissible end play ... .10 mm (.004 inch)
(7) Compressor wheel
Illustration 2
(1) Electrical connection
g00298861
Exhaust Manifold
SMCS - 1059
/sisw eb/sisw eb/m /sisw eb/mediase
Illustration 1
g00559857
Refer to Illustration 1 for the tightening sequence. Tighten the plated nuts for the
exhaust manifold to the following torque. ... 44 Nm (33 lb ft)
Refer to Illustration 1 for the tightening sequence. Tighten the nuts that are not plated
for the exhaust manifold to the following torque. ... 50 Nm (37 lb ft)
g00501179
Illustration 2
Muffler
SMCS - 1062
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
g00295475
Illustration 1
(1) Tighten the nuts to the following torque. ... 30 7 Nm (22 5 lb ft)
(2) Tighten the bolts and the nuts to the following torque. ... 55 10 Nm (41 7 lb ft
Camshaft
SMCS - 1210
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
g00618583
Illustration 1
End play of a new camshaft ... 0.10 to 0.41 mm (0.004 to 0.016 inch)
Maximum permissible end play of a worn camshaft ... 0.53 mm (0.021 inch)
(1) Locating pin
(2) Camshaft thrust washer
Thickness of thrust washer ... 5.49 to 5.54 mm (0.216 to 0.218 inch)
Cylinder block recess depth for thrust washer ... 5.46 to 5.54 mm (0.215 to 0.218
inch)
Relationship of thrust washer to cylinder block front face ... -0.05 to +0.08 mm
(-0.002 to +0.003 inch)
(3) Woodruff key
(4) Diameter of camshaft journals
Table 1
Diameters of Camshaft Journals
Camshaft
Journal
Standard Diameter
Service Limit
Diameter (1)
(1)
50.660 mm (1.9945
inch)
50.410 mm (1.9845
inch)
49.900 mm (1.9645
inch)
The service limit is the maximum or the minimum dimension which is specified for a part. A part
which has reached the service limit must be replaced.
Internal clearance of the journal ... 0.06 to 0.14 mm (0.002 to 0.006 inch)
Ver imagen
Illustration 2
g00295323
3. Subtract the base circle (C) from the height (B) of the lobe. The difference is the
actual lobe lift (A) .
4. Specified camshaft lobe lift (A)
Inlet ... 7.62 to 7.69 mm (0.300 to 0.303 inch)
Exhaust ... 7.71 to 7.79 mm (0.304 to 0.307 inch)
Minimum permissible height of lobes ... 7.37 mm (0.290 inch)
1
Ver imagen
g00308804
Illustration 1
Ver imagen
Illustration 1
g00295480
The relief valve for the engine oil pressure should open at the following pressure
setting:
Engines that are not equipped with piston cooling jets ... 340 to 395 kPa (49 to
57 psi)
Engines that are equipped with piston cooling jets ... 415 to 470 kPa (60 to 68
psi)
Engines that are equipped with counter balancer ... 523 kPa (76 psi)
(1) Spring
Length under test force ... 59.8 mm (2.35 inch)
Length under test force for engines that are equipped with counter balancer ...
42.7 mm (1.681 inch)
Test force ... 15.9 to 23.1 N (3.6 to 5.2 lb)
Test force with engines that are equipped with counter balancer ... 34 to 38 N
(7.6 to 8.5 lb)
(2) Outside diameter of plunger ... 18.16 to 18.18 mm (.715 to .716 inch)
Outside diameter of plunger with engines that are equipped with counter balancer ...
15.95 to 15.98 mm (.628 to .629 inch)
Clearance of plunger in bore ... 0.06 to 0.11 mm (.002 to .004 inch)
Clearance of plunger in bore with engines that are equipped with counter balancer ...
0.02 to 0.08 mm (.0008 to .0031 inch)
(3) Diameter of the bore in the valve housing ... 18.24 to 18.27 mm (.718 to .719 inch)
Diameter of the bore in the valve housing with engines that are equipped with counter
balancer ... 16.00 to 16.03 mm (.630 to .631 inch)
(4) Tighten the bolt to the following torque: ... 44 5 Nm (32 4 lb ft)
1
1
Ver imagen
Illustration 1
g00295506
(1) Bolt
Tighten the cover bolts to the following torque: ... 28 Nm (21 lb ft)
When the oil pump is mounted to a balancer unit, tighten the single bolt on the oil pump
cover (not shown) to the following torque: ... 22 Nm (16 lb ft)
Type ... Gerotor pump
Number of lobes
Inner rotor ... 6
Outer rotor ... 7
Ver imagen
Illustration 2
g00295515
Illustration 3
g00295516
Clearance between the inner rotor and the outer rotor ... 0.040 to 0.130 mm (0.0015 to
0.0050 inch)
End play of the rotor assembly. ... 0.03 to 0.10 mm (0.001 to 0.004 inch)
Tighten the bolts that fasten the engine oil pump to the main bearing cap to the
following torque: ... 22 Nm (16 lb ft)
1
The minimum oil pressure at low idle with an ambient temperature of 18 to 20 C (64 to
68 F) is the following value: ... 62 kPa (9 psi)
The minimum oil pressure at high idle and at normal operating temperature is the
following value:
Turbocharged engine ... 280 kPa (40 psi)
Tighten the oil pressure switch, which is located on the left side of the engine block, to
the following torque: ... 7 to 12 Nm (62 to 107 lb in)
1
Ver imagen
Illustration 1
g00877006
Water Pump
SMCS - 1361
/sisw eb/sisw eb/m /sisw eb/mediase
Illustration 1
g00295544
(1) Outside diameter of shaft for drive gear ... 15.91 to 15.92 mm (.626 to .627 inch)
(2) Diameter of bore of drive gear ... 15.86 to 15.88 mm (.624 to .625 inch)
Interference fit of drive gear on shaft ... 0.03 to 0.06 mm (.001 to .002 inch)
(3) Diameter of bore of impeller ... 15.87 to 15.89 mm (.625 to .626 inch)
Outside diameter of shaft for impeller ... 15.91 to 15.92 mm (.626 to .627 inch)
Interference fit of impeller on shaft ... 0.02 to 0.05 mm (.001 to .002 inch)
(4) Diameter of bearing ... 29.990 to 30.000 mm (1.1807 to 1.1811 inch)
Diameter of bore for bearing ... 29.960 to 29.980 mm (1.1795 to 1.1803 inch)
Interference fit of bearing in pump body ... 0.010 to 0.040 mm (.0004 to .0016 inch)
(5) The water pump must be assembled in order to correctly measure the distance from
the impeller boss to the front face of the pump body. Distance ... 8.1 to 8.5 mm (.32 to .
34 inch)
(6) The water pump must be assembled in order to correctly measure the distance of the
gear from the rear face of the pump body. Distance ... 0.6 to 2.6 mm (.02 to .10 inch)
Cylinder Block
SMCS - 1201
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
Illustration 1
g00892504
Typical example
(4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder
block to the following torque. ... 22 Nm (16 lb ft)
(5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to
the following torque.
M6 ... 13 Nm (10 lb ft)
M8 ... 22 Nm (16 lb ft)
(6) Bridge bolt
Use the following procedure in order to install the bridge bolts.
1. Use a straight edge in order to ensure that the bridge is aligned with the front
face of the cylinder block.
2. Evenly tighten the bridge bolts to a torque of 16 Nm (12 lb ft).
3. When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013
Silicone Sealant into the groove at each end of the bridge.
(7) Main bearing cap bolts
Use the following procedure in order to install the main bearing cap bolts.
1. Apply clean engine oil to the threads of the main bearing cap bolts.
2. Put the main bearing caps in the correct position that is indicated by a number on
the top of the main bearing cap. Install the main bearing caps with the locating
tabs in correct alignment with the recess in the cylinder block.
3. Evenly tighten the main bearing cap bolts to a torque of 265 Nm (195 lb ft).
(8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to
3.1670 inch)
(9) Camshaft bearing
Inside diameter of the camshaft bearing for the number 1 camshaft journal ...
50.79 to 50.85 mm (2.000 to 2.002 inch)
Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56
to 55.59 mm (2.187 to 2.189 inch)
Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55
to 50.60 mm (1.990 to 1.992 inch)
Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04
to 50.09 mm (1.970 to 1.972 inch)
Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33
mm (17.367 to 17.375 inch)
g00631670
Illustration 2
(1) Tighten the piston cooling jets to the following torque. ... 27 Nm (20 lb ft)
(2) Diameter of rod ... 1.70 mm (0.067 inch)
(3) Cylinder block
Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the
cylinder block (not shown).
Use the following procedure in order to ensure the correct alignment of the piston
cooling jet.
1. Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out
of the top of the cylinder block.
2. Use the following dimensions to locate the center point of diameter (C) .
Dimension (A) ... 33 mm (1.3 inch)
Dimension (B) ... 21 mm (0.8 inch)
Diameter (C) ... 14 mm (0.6 inch)
Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.
3. Position rod (2) within diameter (C) .
1
Crankshaft
SMCS - 1201
Ver imagen
Illustration 1
g00295557
Note: If a crankshaft that was not originally induction hardened has been remachined,
then the crankshaft must be rehardened. Use one of the process that follow for 20 hours
in order to reharden the crankshaft: nitrocarburizing process and nitriding process
(1) Connecting rod bearing
(2) Top and bottom thrust washer thickness
Standard ... 2.26 to 2.31 mm (0.089 to 0.091 inch)
Oversize ... 2.45 to 2.50 mm (0.096 to 0.098 inch)
(3) Main bearing
Clearance for main bearings ... 0.057 to 0.117 mm (0.0022 to 0.0046 inch)
Bearing width
Center bearing ... 36.32 to 36.70 mm (1.430 to 1.445 inch)
All other bearings ... 31.62 to 31.88 mm (1.245 to 1.255 inch)
Thickness of the bearing at the center
All bearings ... 2.083 to 2.086 mm (0.0820 to 0.0821 inch)
(4) Crankshaft gear
(5) End play of the crankshaft ... 0.05 to 0.38 mm (0.002 to 0.015 inch)
63.22 to 63.24 mm
(2.489 to 2.490 inch)
Undersize Journal
0.51 mm (0.020 inch)
62.96 to 62.98 mm
(2.479 to 2.480 inch)
Undersize Journal
0.76 mm (0.030 inch)
62.71 to 62.73 mm
(2.469 to 2.470 inch)
Connecting rod bearings are available for remachined journals with the following
undersize dimensions:
Undersize ... 0.25 (0.010)
Undersize ... 0.51 (0.020)
Undersize ... 0.76 (0.030)
(7) Dimensions of main journals which are the standard, original size
Width of front journal ... 36.93 to 37.69 mm (1.454 to 1.484 inch)
Width of center journal ... 44.15 to 44.22 mm (1.738 to 1.741 inch)
Width of all other journals ... 39.24 to 39.35 mm (1.545 to 1.549 inch)
Measure the main bearing journals on the crankshaft. See the following chart for
dimensions.
Table 2
Main Bearing Journal
If the bearing journal has been ground beyond this size, then
regrind the bearing journals to the next undersize journal.
75.91 to 75.93 mm
(2.988 to 2.989 inch)
Undersize Journal
0.51 mm (0.020 inch)
75.65 to 75.67 mm
(2.978 to 2.979 inch)
Undersize Journal
0.76 mm (0.030 inch)
75.40 to 75.42 mm
(2.968 to 2.969 inch)
Tighten the bolts for the main bearing journal to the following torque: ... 265 Nm (195
lb ft)
Main bearings are available for remachined journals with the following undersize
dimensions:
Undersize ... 0.25 (0.010)
Undersize ... 0.51 (0.020)
Undersize ... 0.76 (0.030)
Tighten the retaining bolts of the crankshaft pulley (not shown) to the following
torque: ... 115 Nm (85 lb ft)
Apply 9S-3263 Thread Lock Compound to the bolts of the crankshaft damper. Tighten
the bolts (not shown) to the following torque:
M8 bolts ... 35 Nm (26 lb ft)
M12 bolts ... 75 Nm (55 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the cylinder block (not shown)
to the following torque: ... 22 Nm (16 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the bridge (not shown) to the
following torque:
M6 ... 13 Nm (10 lb ft)
M8 ... 18 Nm (13 lb ft)
1
Crankshaft Seals
SMCS - 1160; 1161
Ver imagen
Illustration 1
g00664588
The front oil seal (2) is normally installed to a depth of 7.00 0.25 mm (0.2756
0.0098 inch) (A) from the face of the front oil seal housing (6). The oil seal may cause
wear on the hub of crankshaft pulley (3). This wear may allow oil leakage past the oil
seal. If this situation occurs, the front oil seal can be installed to a depth of 9.3 mm (0.37
inch) from the face of the front oil seal housing.
If a wear sleeve (4) is installed, the front oil seal is installed to a depth of 9.30 mm
(0.366 inch) from the face of the front oil seal housing. When the wear sleeve is
installed, the flange of the wear sleeve does not require removal. If a wear sleeve is
installed, a new front oil seal must be installed.
(5) Tighten three bolts for the crankshaft pulley to the following torque. ... 115 Nm (85
lb ft)
Crankshaft Rear Seal
Engines with 14 Bolt Housing Assembly
Ver imagen
g00317365
Illustration 2
Positions of the crankshaft seal
Position (1) is 0 mm (0.0 inch) from the face of the rear housing.
Position (2) is 4.6 mm (0.18 inch) from the face of the rear housing. Use position (2) if
the crankshaft surface is worn in position (1) .
Position (3) is 6.9 mm (0.27 inch) from the face of the rear housing. Use position (3) if
the crankshaft surface is worn in both of the other positions.
Engines with 10 Bolt Housing Assembly
Connecting Rod
SMCS - 1218
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
Illustration 1
g00295602
(1) Inside diameter of rod for bearing ... 38.89 to 38.92 mm (1.531 to 1.532 inch)
(2) Outside diameter of bearing for piston pin ... 38.94 to 39.03 mm (1.535 to 1.536
inch)
Inside diameter of bearing for piston pin after reaming ... 34.940 to 34.960 mm (1.3758
to 1.3765 inch)
Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .
0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(4) Bearings are available for remachined journals of the crankshaft which have the
following undersize dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)
0.76 mm (.030 inch)
Shell thickness ... 1.835 to 1.842 mm (.0723 to .0726 inch)
Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch)
Bearing clearance ... 0.035 to 0.081 mm (.0014 to .0032 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
(6) Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Turbocharged Engines
(1) Inside diameter of rod for bearing ... 42.07 to 42.09 mm (1.656 to 1.657 inch)
(2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to
1.6613 inch)
Inside diameter of bearing for piston pin after reaming ... 38.120 to 38.140 mm (1.5008
to 1.5015 inch)
Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .
0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(4) Bearings are available for remachined journals of the crankshaft which have the
following undersize dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)
0.76 mm (.030 inch)
Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch)
Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)
Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
(6) Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly
must be turned when the piston and rod assembly are installed. Turning the piston and
connecting rod assembly will prevent the connecting rod from hitting and damaging the
piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on the top of the piston is toward the
front of the engine.
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
The piston height is controlled by the length of the connecting rod. Connecting rods are
supplied in six grades of length. The different grades of length are manufactured by
machining the hole in the piston pin bearing in an off-center position. The different
grades of length are created by the following method:
However, if the crankshaft or the cylinder block is replaced, the required grade of length
of the connecting rods may change.
A correct grade of length of a connecting rod can be ordered for replacement. The
connecting rod includes the piston pin bearing. The piston pin bearing is machined in
order to create the correct grade of length. The piston pin is installed in the connecting
rod at the factory. Table 2 provides the specifications for the grade of length.
Note: The length of the connecting rod is determined by the following method: The
bearing for the crankshaft journal must be removed and the piston pin must be installed.
The original grade of length of the connecting rod is determined when the original
piston pin is installed.
Connecting rods are color coded. The color code is a reference for the length (Y) of the
connecting rod. Refer to Table 2 for the different lengths of connecting rods.
Ver imagen
g00915056
Illustration 2
Table 1
Grade of
Length
"F"
"G"
Color
Red
Orange
"H"
White
"J"
Green
"K"
Purple
"L"
Blue
If a piston pin bearing requires replacement but the connecting rod does not require
replacement, a new piston pin bearing can be ordered. This bearing is partially finished.
The hole in the bearing must be machined off-center to the correct distance in order to
create a connecting rod assembly that is the correct grade of length.
Refer to the Testing and Adjusting manual for the following procedures:
Turbocharged Engines
Serrated Connecting Rods and Flat Connecting Rods
Ver imagen
Illustration 3
g00295602
(1) Inside diameter of rod for bearing ... 43.01 to 43.04 mm (1.693 to 1.694 inch)
(2) Outside diameter of bearing for piston pin ... 43.11 to 43.15 mm (1.697 to 1.699
inch)
Inside diameter of bearing for piston pin after reaming ... 39.723 to 39.738 mm (1.5639
to 1.5645 inch)
Clearance between small end bearing and piston pin ... 0.023 to 0.044 mm (.0009 to .
0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(4) Bearing for connecting rod journal
Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch)
Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)
Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
(6) Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly
must be turned when the piston and rod assembly are installed. Turning the piston and
connecting rod assembly will prevent the connecting rod from hitting and damaging the
piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on top of the piston is toward the front
of the engine.
Hydraulically Fractured Connecting Rods
Ver imagen
Illustration 4
g01064497
Illustration 5
g01064498
(9) Diameter of the bore for the piston pin ... 43.01 to 43.04 mm (1.693 to 1.694 inch)
(10) Distance between bearing centers ... 219.05 to 219.10 mm (8.624 to 8.626 inch)
(11) DPiston and Rings
SMCS - 1214; 1215
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
Illustration 1
g00295711
Note: The word "Front" or an arrow which is marked on the piston crown must be
toward the front of the engine. If the piston crown is not marked, put the narrowest side
of the piston crater toward the side of the engine with the fuel injection pump. The
shortest distance between the edge of the piston crater and the edge of the piston is the
narrowest side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing
from each other.
Note: Refer to Systems Operation, "General Information" for the location of the serial
number.
Naturally Aspirated Engines
(1) Width of groove in piston for top ring ... 2.57 to 2.59 mm (.101 to .102 inch)
Piston Height
Ver imagen
Illustration 2
g00891532
Quadram piston
There are two different designs for the crown of the piston. One design is the Quadram
piston. There is only one grade of piston for the replacement of a Quadram piston.
Grade of piston for service ... L
Height of a Quadram piston above the top face of the cylinder block ... 0.14 to 0.36 mm
(0.005 to 0.014 inch)
Ver imagen
g00891548
Illustration 3
Fastram piston
The other style of piston is the Fastram piston. The piston height above the top face of
the cylinder block is controlled by different grades of height of the piston. Identification
of the height grade is by the letter that is stamped on the top of each piston. The height
grade can be checked by measuring from the center of the piston pin to the top of the
piston. The difference between each grade of height is 0.045 mm (0.0018 inch). Table 1
provides the specifications for the grade of height for a Fastram piston.
Table 1
Height Grades for the Piston
Letter on top of
Piston
Height Dimension
Latest Equivalent
Grade
(1)
70.334 mm (2.7690
inch)
(1)
70.289 mm (2.7673
inch)
(1)
J
70.244 mm (2.7655
inch)
(1)
70.199 mm (2.7637
inch)
(1)
70.154 mm (2.7620
inch)
70.391 mm (2.7713
inch)
70.345 mm (2.7695
inch)
70.299 mm (2.7677
inch)
70.253 mm (2.7659
inch)
70.207 mm (2.7640
inch)
70.161 mm (2.7622
inch)
(1)
Earlier engines
Height of a Fastram piston above the top face of the cylinder block ... 0.38 to 0.50 mm
(0.015 to 0.020 inch)
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
Illustration 4
g00500921
Note: The word "Front" or an arrow which is marked on the piston crown must be
toward the front of the engine. If the piston crown is not marked, put the narrowest side
of the piston crater toward the side of the engine with the fuel injection pump. The
shortest distance between the edge of the piston crater and the edge of the piston is the
narrowest side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing
from each other.
Note: Refer to Systems Operation, "General Information" for the location of the serial
number.
Turbocharged Engines
Note: Install the word "TOP" toward the top of the piston. New top rings have a red
identification mark which must be on the left of the ring gap when the intermediate ring
is installed on an upright piston.
(2) Intermediate ring
Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm
(0.101 to 0.102 inch)
Thickness of intermediate ring ... 2.48 to 2.49 mm (0.097 to 0.098
inch)
Clearance between groove and intermediate ring ... 0.07 to 0.11 mm
(.003 to .004 inch)
Clearance between the ends of an intermediate ring in a cylinder liner
without any wear ... 0.40 to 0.65 mm (.016 to .026 inch)
Note: Install the word "TOP" toward the top of the piston. New intermediate rings have
a green identification mark which must be on the left of the ring gap when the
intermediate ring is installed on an upright piston.
(3) Oil control ring
Width of groove in piston for oil control ring ... 3.54 to 3.56 mm (.139
to .140 inch)
Thickness of oil control ring ... 3.47 to 3.49 mm (.136 to .137 inch)
Clearance between groove and oil control ring ... 0.05 to 0.09 mm
(.002 to .004 inch)
Clearance between the ends of an oil control ring in a cylinder liner
without any wear ... 0.38 to 0.83 mm (.015 to .033 inch)
Note: A pin is used in order to hold both ends of the spring of the oil control ring in
position. The ends of the spring of the oil control ring must be 180 degrees opposite the
end gap of the oil control ring.
(4) Diameter of new piston pin ... 39.694 to 39.700 mm (1.5628 to 1.5630 inch)
Bore for piston pin ... 39.703 to 39.709 mm (1.5631 to 1.5633 inch)
Piston height above cylinder block (not shown) ... 0.36 to 0.50 mm ( .014 to .020 inch)
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iameter for the bore for the connecting rod bearing ... 67.21 to 67.22 mm (2.6460 to
2.6465 inch)
Housing (Front)
SMCS - 1151
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
Illustration 1
Front housing and front cover
Ver imagen
g00753583
g00753612
Illustration 2
9U-6200 Front Cover Installer
Ver imagen
Illustration 1
g00295804
(3) Tighten the bolt for the camshaft gear to the following torque. ... 95 Nm
(70.0682 lb ft)
(4) Idler gear and hub
Diameter of the idler gear bore ... 57.14 to 57.18 mm
(2.250 to 2.251 inch)
Width of the idler gear and split bearing assembly ... 30.14 to 30.16 mm (1.186
to 1.187 inch)
Inside diameter of the idler gear bearing ... 50.78 to 50.80 mm (1.999 to 2.000
inch)
Outside diameter of the idler gear hub ... 50.70 to 50.74 mm
(1.996 to 1.998 inch)
Clearance of the bearing on the idler gear hub ... 0.04 to 0.10 mm
(0.002 to 0.004 inch)
Idler gear end play ... 0.10 to 0.20 mm (0.004 to 0.008 inch)
Maximum permissible end play ... 0.38 mm (0.015 inch)
Backlash (minimum) ... 0.08 mm
(0.003 inch)
(5) Tighten the bolts for the idler gear to the following torque: ... 44 Nm (33 lb ft)
(6) Crankshaft gear
Diameter of the bore of the crankshaft gear ... 47.625 to 47.650 mm (1.8750 to
1.8760 inch)
Outside diameter of the crankshaft for the crankshaft gear ... 47.625 to 47.645
mm (1.8750 to 1.8758 inch)
Clearance of the crankshaft gear on the crankshaft for a press fit ... 0.015 0.035
mm (0.0006 0.0014 inch)
(7) Oil pump idler gear
Inside diameter of the bearing ... 22.230 to 22.260 mm (0.8750 to 0.8766 inch)
Outside diameter of the idler gear shaft ... 22.19 to 22.21 mm (0.873 to 0.874
inch)
Clearance of the gear on the shaft ... 0.020 to 0.066 mm (0.0008 to 0.0026 inch)
Idler gear end play ... 0.012 to 0.643 mm (0.0005 to 0.0253 inch)
Timing gear backlash (minimum) ... 0.08 mm (0.003 inch)
End play of idler gear ... 0.07 to 0.23 mm (0.0028 to 0.0091 inch)
Thickness of thrust washer for idler gear ... 4.14 to 4.29 mm (0.1630 to 0.1689 inch)
Number of teeth on idler gear ... 37
Inside diameter of bushes in balancer frame and end cover ... 38.133 to 38.174 mm
(1.5013 to 1.5029 inch)
Diameter of spigots for balance weights ... 38.054 to 38.069 mm (1.4982 to 1.4988
inch)
Fit of spigot in bush ... 0.064 to 0.120 mm (0.0025 to 0.0047 inch)
End play of balance weights ... 0.19 to 0.40 mm (0.0075 to 0.0157 inch)
Backlash of gears on balance weights ... 0.10 to 0.27 mm (0.0039 to 0.0106 inch)
Backlash of drive gear to spline on balance weight ... 0.05 to 0.20 mm (0.0020 to 0.0079
inch)
Number of teeth on drive gear ... 24
Number of teeth on spline on balance weight ... 16
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0
Ver imagen
Illustration 1
g00295950
(1) Tighten the bolts of the flywheel housing to the following torque:
The M10 bolts for the cast iron flywheel housing ... 44 Nm (32 lb ft)
The M12 bolts that are stamped "8.8" for the cast iron flywheel
housing ... 75 Nm (55 lb ft)
The M10 bolts that are stamped "10.9" for the cast iron flywheel
housing ... 63 Nm (46 lb ft)
The M12 bolts that are stamped "10.9" for the cast iron flywheel
housing ... 115 Nm (85 lb ft)
The M10 bolts that are for the aluminum flywheel housing ... 70 Nm
(52 lb ft)
(2) The maximum temperature for heating the flywheel ring gear for installation ... 250
C (482 F)
(3) Tighten flywheel bolts to the following torque: ... 105 Nm (77 lb ft)
Flywheel Housing Runout
Face Runout
Ver imagen
Illustration 2
g00295952
Maximum permissible face runout of the flywheel housing ... 0.20 mm (0.008 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct
procedure to measure the runout.
Bore Runout
Ver imagen
Illustration 3
g00295954
Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct
procedure to measure the runout.
Flywheel Runout
Face Runout
Ver imagen
Illustration 4
g00295955
Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing".
Outside Diameter Runout
Ver imagen
Illustration 5
g00295956
Maximum permissible bore runout of the flywheel housing ... 0.30 mm (0.012 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct
procedure to measure the runout
Electric Starting Motor
SMCS - 1453
Ver imagen
Illustration 1
Starting Motor (Side View)
Ver imagen
g00295928
Illustration 2
g00295930
End view of the starting motor which shows the electrical connections
(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 Nm (18 to 24 lb
ft)
(2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 Nm (9
to 12 lb in)
Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb)
Minimum resistance of the starter cable at 200 C (392 F) and at 12 volts ... 0.0017
ohms
Start Relays
9G-4368 Relay
Ver imagen
Illustration 3
g00731492
Illustration 4
g00295932
Commutator
New diameter ... 45 mm (1.77 inch)
Minimum diameter ... 42.5 mm (1.67 inch)
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