Kenr6230 00 PDF

KENR6230-00
August 2006
Specifications
2506-15 Industrial Engine
MGA (Engine)
MGB (Engine)
MGD (Engine)
This document has been printed from SPI². Not for Resale
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Perkins
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Perkins dealers have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
KENR6230 3
Table of Contents
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Transfer Pump ............................................. 4
Fuel Filter Base .................................................... 5
Fuel Filter (Primary) .............................................. 5
Fuel Priming Pump .............................................. 6
Electronic Unit Injector Mechanism ..................... 6
Electronic Unit Injector Rocker Arm ...................... 7
Electronic Unit Injector Wiring ............................... 7
Valve Mechanism ................................................. 8
Valve Mechanism Cover ...................................... 8
Cylinder Head Valves ........................................... 9
Cylinder Head ...................................................... 11
Turbocharger ....................................................... 13
Exhaust Manifold ................................................. 14
Exhaust Elbow ..................................................... 14
Camshaft ............................................................. 15
Engine Oil Filter Base .......................................... 15
Engine Oil Pump .................................................. 16
Engine Oil Pan ..................................................... 17
Water Lines ........................................................... 17
Water Temperature Regulator .............................. 18
Water Pump ......................................................... 18
Cylinder Block ...................................................... 19
Cylinder Liner ....................................................... 21
Crankshaft ........................................................... 22
Crankshaft Seals ................................................. 22
Vibration Damper ................................................. 23
Connecting Rod Bearing Journal ......................... 23
Main Bearing Journal ............................................ 23
Connecting Rod ................................................... 24
Piston and Rings .................................................. 25
Housing (Front) ..................................................... 26
Gear Group (Front) ............................................... 26
Flywheel ............................................................... 28
Flywheel Housing ................................................ 29
Flywheel Housing Cover ...................................... 29
Belt Tightener ....................................................... 30
Fan Drive ............................................................. 30
Alternator and Regulator ...................................... 31
Alternator Mounting ............................................. 31
Electric Starting Motor ......................................... 32
Coolant Temperature Sensor ............................... 32
Fuel Temperature Sensor ..................................... 33
Engine Oil Pressure Sensor ................................. 33
Atmospheric Pressure Sensor .............................. 33
Inlet Manifold Air Pressure Sensor ....................... 33
Inlet Air Temperature Sensor ................................ 34
Speed/Timing Sensor .......................................... 34
Index Section
Index ..................................................................... 35
4 KENR6230
Specifications Section i02576024
Fuel Transfer Pump

i02555165
Engine Design
2506
g01096864
Illustration 1
g01290776
Cylinder and valve location Illustration 2
(A) Inlet
(B) Exhaust (1) Pressure regulating valve
(C) Flywheel end of engine
(2) Inlet port
Bore ........................................ 137.2 mm (5.40 inch)
(3) Weep hole
Stroke ..................................... 171.5 mm (6.75 inch)
(4) Outlet port
Displacement ........................... 15.2 L (927.56 cu in)
Cylinder arrangement .................................... In-Line
Valves per cylinder .................................................. 4
The adjustment for the inlet valve lash is the following

value. .............. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
The adjustment for the exhaust valve lash is the

following value. ................................ 0.76 ± 0.08 mm
(0.030 ± 0.003 inch)
Firing order (injection sequence) ........ 1, 5, 3, 6, 2, 4
Crankshaft rotation ........................ counterclockwise
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.
g01290775
Illustration 3
(5) Bolts
KENR6230 5
Tighten the bolts to the following torque. .. 47 N·m i02570891

(35 lb ft)
Fuel Filter (Primary)
When the fuel transfer pump is using diesel fuel, the
fuel transfer pump has the following specifications.
Run the pump at 2940 rpm. The bypass pressure

must be between 716 kPa (103.8 psi) and 786 kPa
(114.0 psi).
Run the pump at 840 rpm. The flow at 550 kPa

(80 psi) must be 3.0 L/min (0.80 US gpm).
Run the pump at 100 rpm with the inlet to the

atmosphere for 10 seconds. The pump must maintain
a vacuum of 60 kPa (9 psi) for 30 seconds once the
inlet is blocked.
Run the pump at 2940 rpm. The flow at 650 kPa

(94 psi) must be 4.5 L/min (1.19 US gpm).
i02570754
Fuel Filter Base
g01287986
Illustration 5
Typical example
(1) Tighten the primary fuel filter housing (1)

to the fuel filter base (2) to the following
torque. ......................... 80 ± 10 N·m (59 ± 7 lb ft)
(2) Fuel filter base
(3) Tighten the secondary fuel filter housing (3)

to the fuel filter base (2) to the following
torque. ......................... 80 ± 10 N·m (59 ± 7 lb ft)
(4) Drain Plugs
g01287856
Illustration 4
(1) Retaining setscrews ................. 47 N·m (35 lb ft)
(2) Plug ........................................... 15 N·m (11 lb ft)
(3) Plug ........................................... 15 N·m (11 lb ft)
(4) Plug .......................................... 41 N·m (30 lb ft)
6 KENR6230
i02570837 i02555267
Fuel Priming Pump Electronic Unit Injector

Mechanism
g01287938
Illustration 6
Typical example g01096477
Illustration 7
(1) Tighten the bolt to the following torque. ... 25 N·m (1) Cap nut
(220 lb in)
Tighten the cap nuts to the following
(2) Priming pump torque. .................... 2.5 ± 0.25 N·m (22 ± 2 lb in)
(3) Tighten the bolt to the following torque. ... 12 N·m (2) Locknut for the adjustment screw
(105 lb in)
Tighten the locknut for the adjustment screw to
the following torque. .. 100 ± 10 N·m (75 ± 7 lb ft)
(3) Unit injector height

Adjust the unit injector height to the following
dimension. ...... 78.0 ± 0.2 mm (3.07 ± 0.01 inch)
(4) Unit injector clamp retaining bolt
1. Tighten the unit injector clamp retaining bolt to

55 ± 10 N·m (41 ± 7 lb ft).
2. Loosen the retaining bolt until the bolt is finger

tight.
3. Tighten the retaining bolt again to 55 ± 10 N·m

(41 ± 7 lb ft).
(5) Spacer
(6) Unit injector clamp
KENR6230 7
(7) O-ring seals i02555277
Before installation of the unit injector, lubricate the Electronic Unit Injector Wiring
top two O-ring seals with clean engine oil.
Note: Refer to Testing and Adjusting, “Electronic Unit

Injector - Adjust” for the correct procedure for setting
the lash on the electronic unit injector.
i02555275
Electronic Unit Injector Rocker

Arm
g01099897
Illustration 9
(1) Tighten the nuts that are on the cap assembly to

the following torque. .................... 2.5 ± 0.25 N·m
g01105353 (22 ± 2 lb in)
Illustration 8
Position connectors so that the wires are not
(A) Bore in the rocker arm bearing for the rocker contacting any other surfaces.
arm shaft
Dimension for bore of new bearing after
installation ............................ 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)
Maximum dimension for worn
bearing ........................ 40.193 mm (1.5824 inch)
(1) Location of bearing joint
The rocker arm bearing must not extend beyond

either face of the rocker arm.
8 KENR6230
i02556086 (6) Camshaft

Valve Mechanism (7) Valve bridge assembly
i02571284
Valve Mechanism Cover
g00579258
Illustration 10
Typical example
(1) Valve rocker arm assembly

g01288232
Illustration 11
(2) Adjusting the screw locknut
Valve cover
Tighten the locknut to the following
torque. ........................... 30 ± 7 N·m (22 ± 5 lb ft)
(3) Bolt
Tighten the bolts to the following
torque. ..................... 109 ± 15 N·m (80 ± 11 lb ft)
(4) Rocker arm shaft

Diameter of a new rocker arm
shaft ..................................... 40.000 ± 0.010 mm
(1.5748 ± 0.0004 inch)
Bore in a new rocker arm bearing for the rocker
arm shaft .............................. 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)
(5) Valve lash

Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Exhaust valves .......................... 0.76 ± 0.08 mm
g01288233
(0.030 ± 0.003 inch) Illustration 12
Tightening sequence
Note: Refer to Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust” for the correct procedure on Refer to Illustration12 for the tightening sequence
setting the engine valve lash. of the valve cover bolts.
KENR6230 9
(1) Bolts Load at minimum operating length .... 900 ± 45 N

(202 ± 10 lb)
Torque for bolts ......................... 20 N·m (15 lb ft) Free length after test ...... 76.70 mm (3.020 inch)
Outside diameter ............ 36.30 mm (1.429 inch)
(2) Valve mechanism cover
(2) Valve guide
(3) Harness connector
Bore of installed valve guide (new
(4) Integral breather parts) ..................................... 9.502 ± 0.026 mm
(0.3741 ± 0.0010 inch)
i02575732 Maximum recommended diameter of the valve
guide bore ..................... 9.538 mm (0.3755 inch)
Cylinder Head Valves
Note: Do not use a combination of a valve and
a valve guide that has a difference of 0.13 mm
(0.005 inch) or more.
(3) Height to top of valve guide ..... 35.00 ± 0.50 mm

(1.378 ± 0.020 inch)
(4) Valve recess

Inlet (new parts) ........................ 2.20 to 2.80 mm
(0.087 to 0.110 inch)
Exhaust (new parts) .................. 1.20 to 1.80 mm
(0.047 to 0.071 inch)
Inlet (reconditioned parts) ......... 2.20 to 3.29 mm
(0.087 to 0.129 inch)
Exhaust (reconditioned parts) ... 1.20 to 2.29 mm
(0.0472 to 0.090 inch)
g00645577
Illustration 13
Note: Apply engine oil to the valve stems prior to

installation in the cylinder head.
(1) Valve springs

Inner Spring Illustration 14
g00640401
Assembled length ........... 60.14 mm (2.368 inch)

Load at assembled length ................. 150 ± 12 N (5) Valve face angle
(34 ± 3 lb)
Operating length (minimum) ............... 44.02 mm Inlet .................................... 29 1/4 ± 1/4 degrees
(1.733 inch) Exhaust .............................. 44 1/4 ± 1/4 degrees
Load at minimum operating length .... 400 ± 18 N
(90 ± 4 lb) (6) Valve stem diameter
Free length after test ...... 71.70 mm (2.823 inch) New valve stem diameter ...... 9.427 ± 0.010 mm
Outside diameter ............ 25.17 mm (0.991 inch) (0.3711 ± 0.0004 inch)
Outer Spring Minimum recommended valve stem
Assembled length ........... 67.12 mm (2.643 inch) diameter ........................ 9.309 mm (0.3665 inch)
Load at assembled length ................. 320 ± 25 N
(72 ± 6 lb) (7) Diameter of valve head
Operating length (minimum) ............... 51.00 mm
(2.008 inch) Inlet ................................. 47.00 mm (1.850 inch)
Exhaust ........................... 41.81 mm (1.646 inch)
10 KENR6230
(8) Minimum recommended valve lip thickness

Inlet ................................... 2.75 mm (0.108 inch)
Exhaust ............................. 2.05 mm (0.081 inch)
(9) Overall length of valve

Inlet ........................................ 202.00 ± 0.45 mm
(7.953 ± 0.018 inch)
Exhaust .. 202.06 ± 0.45 mm (7.955 ± 0.018 inch)
g00564825
Illustration 15
(10) Width of the valve seat

Inlet ............................... 2.377 mm (0.0936 inch)
Exhaust ......................... 1.508 mm (0.0594 inch)
(11) Depth of bore in the cylinder head for the valve

seat insert
Inlet ......... 14.00 ± 0.05 mm (0.551 ± 0.002 inch)
Exhaust ... 13.90 ± 0.05 mm (0.547 ± 0.002 inch)
(12) Inside diameter of valve seat insert

Inlet ......... 41.00 ± 0.50 mm (1.614 ± 0.020 inch)
Exhaust ... 36.50 ± 0.50 mm (1.437 ± 0.020 inch)
(13) Angle of valve seat face

Inlet .......................................... 30.25 ± 1 degree
Exhaust .................................... 45.25 ± 1 degree
(14) Outside diameter of valve seat insert

Inlet .. 48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)
Exhaust ................................ 42.840 ± 0.013 mm
(1.6866 ± 0.0005 inch)
Diameter of the bore in the cylinder head for the
valve seat insert
Inlet .. 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)
Exhaust ................................ 42.774 ± 0.025 mm
(1.6840 ± 0.0010 inch)
KENR6230 11
i02555225
Cylinder Head
g01025099
Illustration 16
Table 1
Required Tools
Tool Part Number Part description
A CV60895 POWERPART
Special Lubricant
The bolts that are marked “X” are 216 mm (8.5 inch)
long. The remainder of the bolts are 194 mm
(7.6 inch) long.
Apply Tooling (A) to the bolt threads and both sides

of the washers. Tighten the bolts in the following step
sequence:
g00643834
Illustration 17
1. In a numerical sequence, tighten bolts 1 through
26. (A) Cylinder Head Thickness
Torque for bolts ....... 270 ± 15 N·m (200 ± 11 lb ft) Thickness of a new cylinder
head ...... 120.00 ± 0.15 mm (4.724 ± 0.006 inch)
2. In a numerical sequence, tighten bolts 1 through Minimum thickness of a used cylinder
26. head ................................. 119.7 mm (4.713 inch)
Torque for bolts ....... 450 ± 15 N·m (330 ± 11 lb ft)
3. In a numerical sequence, again tighten bolts 1

through 26.
Torque for bolts ....... 450 ± 15 N·m (330 ± 11 lb ft)
Note: The flatness of the cylinder head should be

within a total of 0.13 mm (.005 inch). Also, the flatness
of the cylinder head should be within a maximum of
0.05 mm (.002 inch) for any 150 mm (5.9 inch) span.
12 KENR6230
g01007827
Illustration 18
(27) Oil gallery
(28) Bearing joint
(29) Oil holes
(30) Camshaft bearing
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
g01067535
Illustration 19
(B) Orientation of bearing joint
(28) Bearing joint
(31) Diameter of Camshaft Bore
(31) Diameter of camshaft bore .. 90.985 ± 0.020 mm

(3.582 ± 0.001 inch)
Orientation of bearing joint

(B) ..................................... 15° ± 5° above horizontal
KENR6230 13
g01060954
Illustration 20
The depth of installation of the camshaft bearings is

very important. Install bearings (30) to the following
depths:
Installation depth for camshaft bearings (30)

C ................. 19.12 ± 0.50 mm (0.75 ± 0.02 inch)
D ................... 154.7 ± 0.5 mm (6.09 ± 0.02 inch)
E ................. 326.2 ± 0.5 mm (12.84 ± 0.02 inch)
F ................. 497.6 ± 0.5 mm (19.59 ± 0.02 inch)
G ................. 669.1 ± 0.5 mm (26.34 ± 0.02 inch)
H ................. 840.5 ± 0.5 mm (33.09 ± 0.02 inch)
I ................. 1012.0 ± 0.5 mm (39.84 ± 0.02 inch)
i02576026
Turbocharger
g01290782
Illustration 21
Table 2
Typical example
Required Tools
Tool Part Number Part Description (1) Tighten the clamp nuts to the following
torque. ...................................... 14 N·m (10 lb ft)
A CV60889 Anti-Seize
Compound
Lightly hit the clamps with a soft faced hammer.
Again tighten the clamp nuts to the following
torque. ............................................. 14 N·m (10 lb ft)
(2) Tighten the bolts to the following torque. .. 47 N·m

(35 lb ft)
(3) Apply Tooling (A) to the fasteners for the

turbocharger and tighten to the following
torque. ...................................... 55 N·m (41 lb ft)
14 KENR6230
i02571665 Apply Tooling (A) to the threads of the studs that

engage the locknuts.
Exhaust Manifold Tighten the studs (4) in the cylinder head to the
following torque. ....................... 35 N·m (26 lb ft)
i02576087
Table 3
Exhaust Elbow
Required Tools
Tool Part Number Part Description
Compound
g01290855
Illustration 24
g01288578 Typical example
Illustration 22
Typical example
(1) Tighten the nut for the clamp to the following
torque. ................................... 13.5 N·m (10 lb ft)
g01100255
Illustration 23
Tightening sequence
(1) Spacer
(2) Washer
(3) Tighten the locknuts to the following

torque. ...................................... 38 N·m (28 lb ft)
(4) Taperlock studs
KENR6230 15
i02555167 Injector lobe ................ 10.336 mm (0.4069 inch)

Camshaft (7) Camshaft lobe height
(8) Base circle
To find the lobe lift, use the procedure that follows:
1. Measure camshaft lobe height (7).
2. Measure base circle (8).
3. Subtract the base circle measurement (Step

2) from the camshaft lobe height (Step 1). The
difference is the actual lobe lift.
Maximum permissible difference between the actual

lobe lift (Step 3) and the specified lobe lift of a new
camshaft ................................... 0.1 mm (0.004 inch)
g00562795
Illustration 25
(1) Exhaust lobe
(2) Injector lobe
(3) Inlet lobe
Note: Lubricate the camshaft lobes with clean engine

oil.
(4) Bearing journal

g00544839
Diameter of the bearing Illustration 27
journals ... 84.85 ± 0.02 mm (3.341 ± 0.001 inch)
(9) Screw
Note: Lubricate the camshaft bearings with clean
engine oil prior to installing the camshaft. Tighten the screws that fasten the cover to the
cylinder head to the following torque. .. 6 ± 1 N·m
(5) Front of camshaft (53 ± 9 lb in)
i02571743
Engine Oil Filter Base
Table 4
Required Tools
A 21820117 POWERPART
Thread Lock and
g00466866
Illustration 26 Nut Lock
(6) Camshaft lobe lift

Specified camshaft lobe lift
Exhaust lobe ................. 8.515 mm (0.3352 inch)
Inlet lobe ....................... 9.431 mm (0.3713 inch)
16 KENR6230
(4) Tighten the plug to the following

torque. ..................... 100 ± 15 N·m (74 ± 11 lb ft)
i02571764
Engine Oil Pump
g01095364
Illustration 28
(1) Apply Tooling (A) on the tapered end of the stud

to the following dimension. .......... 10.5 ± 1.5 mm
(0.41 ± 0.06 inch)
Tighten the stud to the following torque. .. 68 ± 7 N·m

(50 ± 5 lb ft)
(2) Apply engine oil to the oil filter seal. Put the oil
filter in position. Turn the oil filter by hand until the Illustration 30
g00566332
seal makes contact with the base. Additionally
tighten the oil filter by 3/4 of a turn. NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
(1) Diameter of shafts ............... 22.217 ± 0.005 mm

(0.8747 ± 0.0002 inch)
Diameter of bores in cover for

shafts .... 22.258 ± 0.008 mm (0.8763 ± 0.0003 inch)
(2) Length of gears .................... 79.375 ± 0.025 mm

(3.1250 ± 0.0010 inch)
Depth of bores for gears ............ 79.502 ± 0.020 mm

g01095366
Illustration 29 (3.1300 ± 0.0008 inch)
View A-A
(3) Spring
(3) Spring
Length under test force ...... 117.9 mm (4.64 inch)
Length under test force ... 55.25 mm (2.175 inch) Test force ................... 150 ± 8 N·m (110 ± 6 lb ft)
Test force ...................... 76 ± 5.8 N (17 ± 1.30 lb) Free length after test ........ 152.9 mm (6.02 inch)
Free length after test .......... 93.7 mm (3.69 inch) Outside diameter ................. 27 mm (1.063 inch)
Outside diameter ................ 20.6 mm (0.81 inch)
The filter and the cooler bypass valves
will open with the following pressure
difference. ................... 255 ± 20 kPa (37 ± 3 psi)
KENR6230 17
g00566395 g01284984
Illustration 31 Illustration 33
Pump body Tightening sequence
(4) Bearings (1) Joint

Install the bearings so the bearings are even with (2) Washer
the outside of the pump body.
(A) Position of bearing joint from the centerline (3) Plug
through bearing bores ........ 30 ± 15 degrees
Torque ....................................... 45 N·m (33 lb ft)
i02571769 (4) Engine Oil Pan

Engine Oil Pan (5) Tighten the bolts to the following torque. .. 47 N·m
(35 lb ft)
i02556087
Water Lines
g01073444
Illustration 34
g01288663
Illustration 32
Typical example (1) Seal bores
Apply a light coat of glycerin to the seal bores.
18 KENR6230
i02556089 i02556088
Water Temperature Regulator Water Pump
g00285471
Illustration 35
Typical example
Completely open temperature ........... 98 °C (208 °F)
Minimum opening distance at 98 °C

(208 °F) ..................................... 10.4 mm (0.41 inch)
g00568324
Illustration 36
Typical example
(1) Bolt
Tighten the bolt that holds the impeller to the
following torque. ............ 39 ± 3 N·m (29 ± 2 lb ft)
(2) The shaft diameter at the carbon seal

assembly seat area is the following
dimension. ............................... 19.10 ± 0.01 mm
(0.7520 ± 0.0004 inch)
(3) Coolant seal
Press the seal assembly onto the water pump shaft

until the stationary cup is fully seated in the pump
housing.
(4) Oil seal
Install the oil seal with the primary lip toward the
water pump drive gear. Press the oil seal into the
counterbore with a press.
KENR6230 19
i02555212
Cylinder Block
g01279769
Illustration 37
Right side view
(1) Dowel (3) Dowel

The dowel extends above the top surface The dowel extends above the top surface
of the cylinder block by the following of the cylinder block by the following
distance. ...................................... 18.5 ± 0.5 mm distance. ...................................... 16.0 ± 0.5 mm
(0.73 ± 0.02 inch) (0.63 ± 0.02 inch)
(2) Spacer plate (4) Dowel

Thickness of the spacer plate .. 8.585 ± 0.025 mm The dowel extends above the top surface
(0.3380 ± 0.0010 inch) of the cylinder block by the following
distance. ...................................... 20.0 ± 0.5 mm
Thickness of the gasket that is placed (0.79 ± 0.02 inch)
between the spacer plate and the cylinder
block .......................................... 0.20 ± 0.02 mm (5) Plug
(0.008 ± 0.001 inch)
Tighten the plug to the following
Cylinder liner projection above the spacer torque. ............................................. 70 ± 10 N·m
plate ...................................... 0.025 to 0.152 mm (52 ± 7 lb ft)
(0.0010 to 0.0060 inch)
20 KENR6230
(6) Dowel
The dowels extend past the end of the cylinder
block by the following distance. ... 19.1 ± 0.5 mm
(0.75 ± 0.02 inch)
g00284986
Illustration 38
View A-A
g01096193
Illustration 40
Front view
(8) Dimension from the centerline of the crankshaft

bearing bore to the top of the cylinder block
New ....................................... 425.45 ± 0.15 mm
(16.750 ± 0.006 inch)
Minimum ........................................... 425.02 mm
g00562849
Illustration 39 (16.733 inch)
View B-B
Note: The total flatness of the top contact surface
(7) Installation depth of the plug .......... 2.0 ± 2.0 mm of the cylinder block must be within 0.10 mm
(0.08 ± 0.08 inch) (0.004 inch). The flatness must also be within
0.05 mm (0.002 inch) for any 177.5 mm (6.99 inch)
section of the surface.
(9) Bore in the cylinder block for the main bearings
(10) Main bearing cap

Main bearing cap width ...... 215.900 ± 0.025 mm
(8.5000 ± 0.0010 inch)
Width of the cylinder block for the main bearing
cap ..................................... 215.900 ± 0.013 mm
(8.5000 ± 0.0005 inch)
(11) New dimension from the centerline of the

crankshaft bearing bore to the bottom of the
cylinder block pan rails .......... 165.10 ± 0.10 mm
(6.500 ± 0.004 inch)
(12) Main bearing cap bolts
KENR6230 21
(15) Straight thread O-ring plug
(16) Piston cooling jet

To prevent damage to the piston cooling jets
during service, the piston cooling jets must be
removed.
Minimum permissible clearance between
the piston, the piston cooling jet, and the
crankshaft ............................................. 0.63 mm
(0.025 inch)
i02555235
Illustration 41
g01062353 Cylinder Liner
Torque-turn tightening method for main bearing cap bolts
Use the following procedure in order to tighten the

main bearing cap bolts:
1. Apply clean engine oil to the threads of the bolts.
2. Tighten the bolts first on the bearing tab side (13)

of the cap.
Torque for bolts ............................... 260 ± 14 N·m

(190 ± 10 lb ft)
3. Tighten the bolts on the opposite end (14) of the

cap.
Torque for bolts ............................... 260 ± 14 N·m

(190 ± 10 lb ft)
g00288159
Illustration 43
4. Put a mark on each bolt and each cap.
(1) Bore in new liner ....................... 137 ± 0.025 mm
5. Tighten the bolts on the opposite end of the (5.40 ± 0.0010 inch)
bearing tab (14) from the mark to angle (A).
(2) Thickness of flange on liner ... 8.890 ± 0.020 mm
Angle (A) ....................... 120 ± 5 degrees (2 flats) (0.3500 ± 0.0008 inch)
6. Tighten the bolts on the bearing tab side (13) of The minimum thickness of the part that can be used
the cap from the mark to the following value. again is the following value. ...................... 8.870 mm
(0.3492 inch)
Angle (A) ....................... 120 ± 5 degrees (2 flats)
(3) Filler band
g01096201
Illustration 42
Right side view
22 KENR6230
i02555185 i02555201
Crankshaft Crankshaft Seals
g00955608
Illustration 44
(1) The length of the dowel out of the

crankshaft ......... 4.1 ± 0.5 mm (0.16 ± 0.02 inch)
(2) The maximum length of the dowel out of the

crankshaft ........................... 6.4 mm (0.252 inch) g00960341
Illustration 45
(3) Main bearing journal

(1) Front crankshaft seal
(4) Connecting rod bearing journal
The front seal should be installed even with
Refer to Specifications, “Connecting Rod Bearing the front of the crankshaft with the following
Journal” and Specifications, “Main Bearing Journal” tolerance. ...................................... −0.13 to 0.13 mm
for more information about the crankshaft journals. (−0.005 to 0.005 inch)
(5) Crankshaft end play ................... 0.11 to 0.57 mm The seal driver should not contact the seal within the
(0.004 to .022 inch) following diameter. ....................... 177.80 ± 0.25 mm
(7.000 ± 0.001 inch)
The maximum permissible end play with used
bearings .................................. 0.89 mm (0.035 inch) (2) Rear crankshaft seal
(6) Timing gear Install the rear seal to the following distance from the
end of the crankshaft. .......................... 5.3 ± 0.6 mm
(0.21 ± 0.024 inch)
The seal driver should not contact the seal within the
following diameter. ....................... 177.80 ± 0.25 mm
(7.000 ± 0.001 inch)
Note: Do not separate the seal from the sleeve.

Replace the seal if the seal is separated from the
sleeve.
KENR6230 23
i02572794 i02555179
Vibration Damper Connecting Rod Bearing

Journal
Table 5
Required Tools Table 6
Tool Part Number Part Description Connecting Rod Bearing Journal
A CV60890 Anti-Seize 97 ± 0.02 mm
Original Size Journal
Compound (3.819 ± 0.0008 inch)
Undersize Journal
96.37 mm (3.794 inch)
0.63 mm (0.025 inch)
Undersize Journal
95.73 mm (3.769 inch)
1.27 mm (0.050 inch)
Clearance between the new bearing and the

journal .................................. 0.062 mm to 0.160 mm
(0.0024 inch to 0.0063 inch)
Maximum permissible clearance between the bearing

and the journal ........................ 0.20 mm (0.008 inch)
i02556083
Main Bearing Journal
g01288983 Table 7
Illustration 46
Main Bearing Journals
(1) Adapter 120.650 ± 0.020 mm
Original Size Journal
(4.7500 ± 0.0008 inch)
(2) Damper
Undersize Journal 120.015 ± 0.020 mm
(3) Tighten the bolts to the following 0.63 mm (0.025 inch) (4.7250 ± 0.0008 inch)
torque. .................................... 105 N·m (77 lb ft) Undersize Journal 119.380 ± 0.020 mm
1.27 mm (0.050 inch) (4.7000 ± 0.0008 inch)
(4) Apply Tooling (A) to the bolts and tighten the bolts
to the following torque. ......... 270 N·m (200 lb ft)
Clearance between the new bearing and the
journal .................................. 0.091 mm to 0.186 mm
(0.0036 inch to 0.0073 inch)
Maximum permissible clearance between the bearing

and the journal ........................ 0.25 mm (0.010 inch)
Table 8
Main Bearing Bore
Original Size of the Bore 129.891 ± 0.013 mm
In the Block (5.1138 ± 0.0005 inch)
Oversize Bore 0.63 mm 130.526 ± 0.013 mm
(0.025 inch) (5.1388 ± 0.0005 inch)
24 KENR6230
i02555176 To install the piston pin bearing, the connecting

rod must be heated. Do not use a torch to heat
Connecting Rod the connecting rod.
Maximum temperature for heating of connecting
rod .............. 175 °C to 260 °C (347 °F to 500 °F)
(A) The bearing junction and the locating hole are

angled 180 degrees from each other. The bearing
junction and the locating hole must be assembled
within area (A).
(X) Tolerance for installation of bearing junction and

locating hole .................................... ± 5 degrees
(2) Dimension
Distance between center of
bearings ...................... 270.76 mm (10.660 inch)
(3) Bore
Bore in the connecting rod bearing after torquing
of the connecting rod bolts .... 103.2 ± 0.013 mm
(4.063 ± 0.0005 inch)
g01024680
Illustration 47
g01026703
Illustration 49
(4) Piston pin

Bore in new bearing for piston
pin ..... 60.035 ± .008 mm (2.3636 ± 0.0003 inch)
Diameter of new piston pin .. 59.975 ± 0.005 mm
(2.3612 ± 0.0002 inch)
Maximum clearance between bearing and worn
piston pin .......................... 0.08 mm (0.003 inch)
g00368754 (5) Crankshaft bearing

Illustration 48
Bore in bearing for
Positioning the piston pin bearing crankshaft ............................ 97.088 ± 0.016 mm
(3.8224 ± 0.0006 inch)
(1) Bore for piston pin bearing Clearance between new bearing and
crankshaft .............................. 0.088 ± 0.036 mm
Dimension ............................ 64.592 ± 0.013 mm (0.0035 ± 0.0014 inch)
(2.5430 ± 0.0005 inch)
Tight fit between connecting rod eye and piston
pin bearing ................................ 0.05 to 0.10 mm
(0.002 to 0.004 inch)
KENR6230 25
i02556085
Piston and Rings
g00898563 g01095989
Connecting rod bolts
(1) Top piston ring
(6) Connecting rod bolts
Install the piston ring with “UP-1” mark toward the
Use the following procedure to tighten the connecting top of the piston.
rod bolts:
There is a clearance between the ends of the piston
1. Put engine oil on the bolt threads and the contact ring. When the piston ring is installed in a cylinder
surfaces before assembly. liner with a bore of 144.975 mm (5.7077 inch), the
clearance is the following value. ........ 0.4 ± 0.10 mm
2. Tighten the bolts in the following order. (0.02 ± 0.004 inch)
Tighten the bolts (A) and (C). ............. 70 ± 4 N·m There is an increase in the clearance between
(52 ± 3 lb ft) the ends of the piston rings for each 0.030 mm
(0.0012 inch) increase in the cylinder liner bore.
Tighten the bolts (B) and (D). ............. 70 ± 4 N·m Increase .................................. 0.08 mm (0.003 inch)
(52 ± 3 lb ft)
(2) Intermediate piston ring
Additionally tighten each bolt. (B) and (D)
...................................................... 60 ± 5 degrees Install the piston ring with “UP-2” mark toward the
top of the piston.
Again, tighten the bolts (A) and (C). ... 70 ± 4 N·m
(52 ± 3 lb ft) There is a clearance between the ends of the piston
ring. When the piston ring is installed in a cylinder
Additionally tighten each bolt. (A) and (C) liner with a bore of 144.975 mm (5.7077 inch), the
...................................................... 60 ± 5 degrees clearance is the following value. ........ 0.6 ± 0.10 mm
(0.02 ± 0.004 inch)
(7) Bolt for piston cooling jet
There is an increase in the clearance between
Tighten the bolt to following torque. ... 40 ± 8 N·m the ends of the piston rings for each 0.030 mm
(30 ± 6 lb ft) (0.0012 inch) increase in the cylinder liner bore.
Increase .................................. 0.08 mm (0.003 inch)
To prevent damage to the piston cooling jet during
service, the piston cooling jets must be removed. (3) Oil Control Ring
Minimum permissible clearance between the piston, The spring ends of the oil control ring should be
the piston cooling jet, and the crankshaft ... 0.63 mm assembled 180 degrees from the ring end gap.
(0.025 inch)
Width of groove in new piston for oil control
ring .............. 4.02 ± 0.010 mm (0.158 ± 0.0004 inch)
26 KENR6230
Thickness of new piston ring .................. 3 ± 0.2 mm (2) Joint

(0.118 ± 0.0079 inch)
(3) Tighten the bolts to the following torque. .. 50 N·m
Clearance between groove and new piston (37 lb ft)
ring .................... 0.8 to 1.2 mm (0.031 to 0.047 inch)
i02573279
There is a clearance between the ends of the piston
ring. When the piston ring is installed in a cylinder
liner with a bore of 144.975 mm (5.7077 inch), the
Gear Group (Front)
clearance is the following value. ...... 0.55 ± 0.15 mm
(0.028 ± 0.006 inch)
There is an increase in the clearance between

the ends of the piston rings for each 0.030 mm Table 9
(0.0012 inch) increase in the cylinder liner bore. Required Tools
Increase .................................. 0.08 mm (0.003 inch)
(4) Piston pin bore A 21820221 POWERPART
Rubber Grease
Bore in piston assembly for
pin ..... 60.0925 ± 0.0075 mm (2.3658 ± 0.0003 inch) B 21820117 POWERPART
Thread Lock and
Nut Lock
Diameter of the new piston pin .. 59.975 ± 0.005 mm
(2.3612 ± 0.0002 inch)
Clearance between the piston pin and the bore in the

piston ...... 0.105 to 0.13 mm (0.0041 to 0.0051 inch)
i02572848
Housing (Front)
g01289048
Illustration 53
(1) Water pump drive gear
g01289008
Illustration 52
(1) Housing
KENR6230 27
g00537659
Illustration 54
Stub shaft for cluster gear
(2) Cluster gear

Apply Tooling (B) to the five bolts for the stub
shaft.
Tighten the five bolts for the stub
shaft in the following sequence. See
Illustration 54 for the numbering of the
bolts. ......................... 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1
Apply Tooling (B) to the four bolts that fasten the
cluster gear to the stub shaft. Illustration 55
g01289844
Tighten the four bolts that fasten the cluster gear (3) Camshaft gear
to the stub shaft to the following torque. .. 28 N·m (12) Sealing plate for the camshaft bolts
(13) Seals
(21 lb ft) (14) Camshaft gear bolts
g00593987
Illustration 56
Camshaft gear
(4) Align the timing mark on the camshaft gear with

the timing mark on the front housing when the
No. 1 piston is at top center.
(3) Camshaft gear
28 KENR6230
Lightly lubricate the O-ring seal on the outside of Tighten the bolt for the oil pump drive gear to the
the camshaft sealing plate with a 50/50 mixture following torque. ....................... 55 N·m (41 lb ft)
of Tooling (A) and clean engine oil. Apply Tool (B)
to the three bolts for the camshaft sealing plate.
i02575327
Tighten the six bolts for the camshaft gear in the
following sequence. refer to 56 for the numbering Flywheel
of the bolts. ........................... 1, 4, 2, 5, 3, 6, 1, 4
Tighten the three camshaft sealing plate bolts to
the following torque. See Illustration 55. .. 12 N·m
(106 lb in)
Tighten the camshaft bolts in the following
Table 10
sequence. See Illustration 56 for the numbering
of the bolts. ........................... 1, 4, 2, 5, 3, 6, 1, 4 Required Tools
Tighten the six camshaft gear bolts to the
following torque. ................... 240 N·m (177 lb ft)
(5) Adjustable idler gear Compound
Install the plate with the oil groove toward the

gear face. Apply Tooling (B) to the three bolts that
fasten the adjustable idler gear to the stub shaft.
Tighten the three bolts for the adjustable
idler gear to the stub shaft to the following
torque. ...................................... 28 N·m (21 lb ft)
Refer to Testing and Adjusting, “Gear Group
(Front) - Time” for the backlash adjustment
procedure.
Backlash between the camshaft gear and the
adjustable idler gear ............... 0.216 ± 0.114 mm
(0.0085 ± 0.0045 inch)
Apply Tooling (B) to the one bolt and five studs Illustration 57
g01095776
for the stub shaft.
Tighten the one bolt and five nuts for the stub Note: Refer to the System Operation, Testing &
shaft to the following torque. ..... 55 N·m (41 lb ft) Adjusting, “Flywheel Runout” for the correct method
of flywheel inspection.
(6) Air compressor gear (if equipped)
(1) Apply Tooling (A) to the threads of the
(7) Idler gear bolts. Tighten the bolts to the following
torque. .................................. 270 N·m (200 lb ft)
Apply Tooling (B) to the one bolt and five studs
for the stub shaft. (2) The maximum temperature of the ring gear for
Tighten the one bolt and five nuts for the stub installation .................................... 316°C (600°F)
shaft to the following torque. ..... 55 N·m (41 lb ft)
Apply Tooling (B) to the three bolts that fasten the
idler gear to the stub shaft.
Tighten the three bolts that fasten the idler gear
to the stub shaft to the following torque. .. 28 N·m
(21 lb ft)
(8) Gear for the fuel transfer pump drive
(9) Align the timing mark on the crankshaft gear with

the timing mark on the cluster gear.
(10) Crankshaft gear
(11) Oil pump drive gear
KENR6230 29
i02575335 3. In a numerical sequence, tighten bolt 1 through

bolt 9 to a torque of 135 N·m (100 lb ft).
Flywheel Housing
4. In a numerical sequence, tighten bolt 10 through
i02555302
Table 11
Required Tools Flywheel Housing Cover
Tool Part Number Part
Description
A CH10879 liquid Gasket
g01072994
Illustration 59
g00551652
Illustration 58
Tightening sequence (1) Bolt
Note: During assembly, inspect the following Tighten the three bolts on the cover to the
components for any foreign materials: the front following torque. ....................... 48 N·m (35 lb ft)
face of the flywheel housing, the two sides of the
flywheel housing gasket and the rear face of the
cylinder block. These components must be free of
the following substances: oil, fuel, water, gasket
adhesive, assembly compounds, and any other
foreign material. Apply a small amount of Tooling (A)
in order to fill the space between the cylinder block,
the flywheel housing, and the oil pan before installing
the oil pan gasket and the oil pan. The components
must be assembled within twenty minutes of applying
the sealant.
Use the following procedure to tighten the flywheel

housing bolts.


30 KENR6230
i02575337 (6) Grease fitting

Belt Tightener
i02575698
Fan Drive
g01285642
Illustration 60
g01290594
Illustration 62
Typical example
g01290260
Illustration 61
(1) Nut
Tighten the nut to the following torque. .. 102 N·m
(75 lb ft)
(2) Tension bolt
(3) Belt Tightener

g01293978
(4) Bolt Illustration 63
Typical example
Tighten the bolt to the following torque. ... 47 N·m
(35 lb ft) (1) Fan drive assembly
(5) Pulley (2) Pulley
KENR6230 31
(3) Tighten the nuts to the following torque. Polarity ........................................... Negative Ground
................................................ 105 N·m (77 lb ft)
Rotation ............................................ Either Direction
(4) Tighten the Bolts to the following torque. .. 47 N·m
(35 lb ft) Minimum full load current at 5000 rpm ...... 42.3 Amp
(5) Tighten the Bolts to the following torque. .. 47 N·m Minimum full load current at 2000 rpm .... 165.8 Amp
(35 lb ft)
Output voltage ............................................. 28 ± 1 V
i02577725
(1) Torque for the ground terminal
Alternator and Regulator nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(2) Torque for the pulley nut .................. 102 ± 7 N·m

(75 ± 5 lb ft)
(3) Torque for the output terminal nut .. 6.2 ± 0.6 N·m
(55 ± 5 lb in)
Regulator Assembly
Voltage setting ................................... No Adjustment
Permissible voltage range ........................ 27 to 29 V
Voltage rating ..................................................... 24 V
i02575721
Alternator Mounting
g00286495
Illustration 64
Typical example
g01290820
Illustration 66
Typical example
(1) Tighten the bolt to the following torque. ... 70 N·m

(52 lb ft)
g00286496
Illustration 65
(2) Alternator
Typical example
32 KENR6230
(3) Tighten the nut to the following torque. .. 105 N·m (3) Tighten the bolts to the following
(77 lb ft) torque. .................................. 215 N·m (160 lb ft)
(4) Tighten the bolt (4) for the link to the following (4) Tighten the nut on the ground terminal to the
torque. .................................... 105 N·m (77 lb ft) following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Tighten the nut on the switch terminal to the

i02578029
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
Electric Starting Motor (6) Tighten the nut on the motor terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
(7) Tighten the nut on the motor frame terminal to

the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
i02576787
Coolant Temperature Sensor
g01294309
Illustration 67
g01291117
Illustration 69
Typical example
(1) Sensor assembly

Tighten the sensor assembly to the following
torque. ..................................................... 20 N·m
g01294310
Illustration 68 (15 lb ft)
When the electric starting motor is viewed from

the drive end, the motor rotates in the following
direction. ................................................... Clockwise
No load conditions at 25°C (77°F)

Speed ...................................... 7643 ± 1683 rpm
Current draw ............................. 76.5 ± 14.5 amp
Voltage ......................................................... 23 V
(1) Tighten the nut on the battery terminal to the

(2) Tighten the nut on the ground terminal to the

KENR6230 33
i02576788 i02576793
Fuel Temperature Sensor Atmospheric Pressure Sensor
g01291117 g01291125
Typical example Typical example
(1) Sensor assembly (1) Sensor assembly

Tighten the sensor assembly to the following Tighten the sensor assembly to the following
torque. ...................................... 20 N·m (15 lb ft) torque. ............................................. 10 N·m (90 lb in)
i02576792 i02578036
Engine Oil Pressure Sensor Inlet Manifold Air Pressure

Sensor
g01291125
Illustration 71
Typical example g01291505
Illustration 73
(1) Sensor assembly Typical example
Tighten sensor assembly to the following (1) Tighten the sensor to the following
torque. ............................................. 10 N·m (90 lb in) torque. ...................................... 10 N·m (90 lb in)
34 KENR6230
i02576790 Ensure that the bracket is installed in the orientation

that is shown.
Inlet Air Temperature Sensor
(3) Tighten the bolt for the sensor to the following
torque. ...................................... 25 N·m (18 lb ft)
Ensure that the sensor is seated before the bolt is

tightened.
Camshaft Position Sensor
g01291117
Illustration 74
Typical example
(1) Sensor assembly g01291129

Illustration 76
Torque for sensor ............................ 20 N·m (15 lb ft) Typical example
(1) Sensor
i02576795
Speed/Timing Sensor (2) Bracket
Ensure that the bracket is installed in the orientation

that is shown.
(3) Tighten the bolt for the sensor to the following

torque. ...................................... 25 N·m (18 lb ft)
Crankshaft Position Sensor
Ensure that the sensor is seated before the bolt is
tightened.
g01291129
Illustration 75
Typical example
(1) Sensor
(2) Bracket
KENR6230 35
Index Section
Index
A H
Alternator and Regulator ....................................... 31 Housing (Front)...................................................... 26

Alternator Mounting ............................................... 31
Atmospheric Pressure Sensor............................... 33
I
B Important Safety Information ................................. 2

Inlet Air Temperature Sensor................................. 34
Belt Tightener ........................................................ 30 Inlet Manifold Air Pressure Sensor ........................ 33
C M
Camshaft ............................................................... 15 Main Bearing Journal............................................. 23

Connecting Rod..................................................... 24
Connecting Rod Bearing Journal........................... 23
Coolant Temperature Sensor................................. 32 P
Crankshaft ............................................................ 22
Crankshaft Seals ................................................... 22 Piston and Rings ................................................... 25
Cylinder Block........................................................ 19
Cylinder Head........................................................ 11
Cylinder Head Valves ............................................ 9 S
Cylinder Liner ........................................................ 21
Specifications Section ........................................... 4
Speed/Timing Sensor ............................................ 34
E Camshaft Position Sensor ................................. 34
Crankshaft Position Sensor ............................... 34
Electric Starting Motor ........................................... 32
Electronic Unit Injector Mechanism ....................... 6
Electronic Unit Injector Rocker Arm....................... 7 T
Electronic Unit Injector Wiring ............................... 7
Engine Design ....................................................... 4 Table of Contents................................................... 3
2506 ................................................................... 4 Turbocharger ......................................................... 13
Engine Oil Filter Base............................................ 15
Engine Oil Pan....................................................... 17
Engine Oil Pressure Sensor .................................. 33 V
Engine Oil Pump.................................................... 16
Exhaust Elbow....................................................... 14 Valve Mechanism .................................................. 8
Exhaust Manifold ................................................... 14 Valve Mechanism Cover........................................ 8
Vibration Damper................................................... 23
F
W
Fan Drive ............................................................... 30
Flywheel ................................................................ 28 Water Lines ........................................................... 17
Flywheel Housing .................................................. 29 Water Pump........................................................... 18
Flywheel Housing Cover........................................ 29 Water Temperature Regulator ............................... 18
Fuel Filter (Primary)............................................... 5
Fuel Filter Base ..................................................... 5
Fuel Priming Pump ................................................ 6
Fuel Temperature Sensor ...................................... 33
Fuel Transfer Pump ............................................... 4
Gear Group (Front)................................................ 26
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.

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Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Specifications Section i02576024

Fuel Transfer Pump

Cylinder arrangement .................................... In-Line

Valves per cylinder .................................................. 4

The adjustment for the inlet valve lash is the following

The adjustment for the exhaust valve lash is the

Firing order (injection sequence) ........ 1, 5, 3, 6, 2, 4

Crankshaft rotation ........................ counterclockwise

Note: The front end of the engine is opposite the

Tighten the bolts to the following torque. .. 47 N·m i02570891

Run the pump at 2940 rpm. The bypass pressure

Run the pump at 840 rpm. The flow at 550 kPa

Run the pump at 100 rpm with the inlet to the

Run the pump at 2940 rpm. The flow at 650 kPa

Fuel Filter Base

(1) Tighten the primary fuel filter housing (1)

(2) Fuel filter base

(3) Tighten the secondary fuel filter housing (3)

(4) Drain Plugs

(1) Retaining setscrews ................. 47 N·m (35 lb ft)

(2) Plug ........................................... 15 N·m (11 lb ft)

(3) Plug ........................................... 15 N·m (11 lb ft)

(4) Plug .......................................... 41 N·m (30 lb ft)

Fuel Priming Pump Electronic Unit Injector

(3) Unit injector height

(4) Unit injector clamp retaining bolt

1. Tighten the unit injector clamp retaining bolt to

2. Loosen the retaining bolt until the bolt is finger

3. Tighten the retaining bolt again to 55 ± 10 N·m

(6) Unit injector clamp

(7) O-ring seals i02555277

Note: Refer to Testing and Adjusting, “Electronic Unit

Electronic Unit Injector Rocker

(1) Tighten the nuts that are on the cap assembly to

(1) Location of bearing joint

The rocker arm bearing must not extend beyond

i02556086 (6) Camshaft

Valve Mechanism Cover

(1) Valve rocker arm assembly

(4) Rocker arm shaft

(5) Valve lash

(1) Bolts Load at minimum operating length .... 900 ± 45 N

(3) Height to top of valve guide ..... 35.00 ± 0.50 mm

(4) Valve recess

Note: Apply engine oil to the valve stems prior to

(1) Valve springs

Assembled length ........... 60.14 mm (2.368 inch)

(8) Minimum recommended valve lip thickness

(9) Overall length of valve

(10) Width of the valve seat

(11) Depth of bore in the cylinder head for the valve

(12) Inside diameter of valve seat insert

(13) Angle of valve seat face

(14) Outside diameter of valve seat insert

Apply Tooling (A) to the bolt threads and both sides

Torque for bolts ....... 450 ± 15 N·m (330 ± 11 lb ft)

3. In a numerical sequence, again tighten bolts 1

Torque for bolts ....... 450 ± 15 N·m (330 ± 11 lb ft)