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3054 MOTORES Cat - Especificaciones
3054 MOTORES Cat - Especificaciones
g00296342
Illustration 1
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.
Type 2 Engines and 7BJ Engines
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g00296424
Illustration 2
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
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
1 1 0
front cylinder.
Fuel Injection Pump
SMCS - 1251; 1290
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)
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g00896561
Illustration 1
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 N·m (35 to 40 lb in)
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 N·m (44 to 53 lb in)
(3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 N·m
(16 lb ft)
(4) Boost control (if equipped)
(5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
N·m (35 to 40 lb in)
(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ...
22 N·m (16 lb ft)
(7) Tighten the flange nuts to the following torque. ... 22 N·m (16 lb ft)
(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 N·m (52 to 60 lb ft)
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Illustration 2
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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
Static Timing
Code Letters Engine Check Fuel Injection
Position Before Piston
on Fuel Angle Pump Mark Angle
TC Position Displacement (1)
Injection Pump (degrees) (1) (degrees) (1)
(degrees)
( 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 )
The information plate on the fuel injection pump is stamped "J609".
( 3 )
"AD70229" and "AD702230" only
( 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)
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g00788020
Illustration 4
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 N·m (44 to 53 lb in)
(3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
N·m (35 to 40 lb in)
(4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 N·m (35 to 40 lb in)
(5) Tighten the flange nuts to the following torque. ... 22 N·m (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
N·m (52 to 60 lb ft)
(8) Tighten the nuts for the high pressure fuel injection line to the following torque. ...
22 N·m (16 lb ft)
(9) Tighten the nut for the end cap to the following torque. ... 22 N·m (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.
Code Letters on Fuel Injection Engine Check Angle Fuel Injection Pump Mark Angle
Pump (degrees) (degrees)
( 1 )
The fuel injection pump is timed with a pin.
( 2 )
The fuel injection pump is coded "2643U211" or "2643U213".
( 3 )
The fuel injection pump is coded "2643U214".
( 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".
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Illustration 5
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 N·m (7 lb ft)
The locking screw prevents the rotation of the drive shaft.
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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 N·m (44 to 53 lb in)
(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 N·m
(35 to 40 lb in)
(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 N·m
(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 N·m
(16 lb ft)
(10) Tighten the nuts for the fuel line to the following torque. ... 22 N·m (16 lb ft)
(11) Tighten the flange nuts to the following torque. ... 22 N·m (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 N·m (52 to 60 lb ft)
Timing Information for the Delphi Fuel Injection Pump
Table 3
Code that is on the Fuel Engine Check Angle Fuel Injection Pump Mark Angle
Injection Pump (degrees) (degrees)
( 1 )
"YA31257" only
( 2 )
"YA50532" only
Table 4
"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
1
Note: Later Delphi Fuel Injection Pumps are timed with a pin.
1 0
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g00308903
Illustration 1
Fuel injection nozzle
(1) Connection for the union nut of the fuel supply line
(2) Threaded hole for the banjo bolt of the leak off line
(3) Clamp
(4) Seal
(5) Spacer
(6) Fuel injector assembly
(7) Seat washer
(1) Tighten the union nut of the high pressure fuel line (not shown) to the following
torque: ... 18 N·m (13.3 lb ft)
(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ...
9.5 N·m (84 lb in)
(3) Tighten the flange bolts (not shown) for the clamp to the following torque: ... 12
N·m (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"
25028 kPa (3630 psi)
"RE"
25028 kPa (3630 psi)
"RF"
25028 kPa (3630 psi)
"RH"
25028 kPa (3630 psi)
"RK"
26903 kPa (3902 psi)
"RM"
25028 kPa (3630 psi)
"RN"
25028 kPa (3630 psi)
"RP"
25028 kPa (3630 psi)
"RR"
25028 kPa (3630 psi)
"RS"
25028 kPa (3630 psi)
"RT"
25028 kPa (3630 psi)
"RU"
25028 kPa (3630 psi)
"RV"
25028 kPa (3630 psi)
( 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
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
g00293085
Illustration 2
Fuel injection nozzle
(1) Connection for the union nut of the fuel supply line
(2) Threaded hole for the banjo bolt of the leak off line
(3) Nut of the fuel injection nozzle
(4) Wire clip
(5) Seat washer
(1) Tighten the union nut of the high pressure fuel line (not shown) to the following
torque: ... 22 N·m (16 lb ft)
(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ...
9.5 N·m (84 lb in)
(3) Tighten the nut of the fuel injection nozzle to the following torque: ... 30 N·m (22 lb
ft)
Note: When the fuel injection nozzle is installed, put a 2.0 mm (.08 inch) bead of 4C-
5591 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"
30406 kPa (4410 psi)
"KM"
30406 kPa (4410 psi)
"KN"
29385 kPa (4262 psi)
"KP"
29385 kPa (4262 psi)
"KR"
29392 kPa (4263 psi)
"KT"
29392 kPa (4263 psi)
"KS"
29392 kPa (4263 psi)
"KU"
29385 kPa (4262 psi)
"KV"
25338 kPa (3675 psi)
"KW"
29385 kPa (4262 psi)
"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"
29385 kPa (4262 psi)
"PD"
27862 kPa (4041 psi)
"PE"
28372 kPa (4115 psi)
"RZ"
25338 kPa (3675 psi)
"SA"
25338 kPa (3675 psi)
"SB"
25338 kPa (3675 psi)
"SC"
25338 kPa (3675 psi)
( 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.
1 1 0
Leakage in 10 seconds ... 0 drops
Fuel Transfer Pump
SMCS - 1256
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g00293216
Illustration 1
Typical example of the fuel transfer pump
Method of drive ... Camshaft
Output pressure during the first ten seconds of cranking:
Normal pressure ... 42 to 70 kPa (6 to 10 psi)
Minimum pressure ... 30 kPa (4.4 psi)
The engine may be equipped with four mounting bolts or four mounting studs with nuts.
Tighten to the following torque: ... 22 N·m (16 lb ft)
Apply 4C-4030 Thread Lock Compound to the first three threads of the mounting bolts
or the mounting studs.
Refer to the Systems Operation, Testing and Adjusting Module, "Fuel System Pressure -
Test" topic in order to test the operation of the fuel transfer pump.
Note: When the fuel transfer pump is installed on the engine, ensure that the camshaft is
on minimum lobe lift and that the bolts are evenly tightened. Failure to follow this
procedure can cause the following conditions: loss of maximum engine power and
1 1 0
damage to the fuel transfer pump.
Rocker Shaft
SMCS - 1102
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g00876530
Illustration 1
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Illustration 1
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Illustration 1
Inlet valves and exhaust valves
Double valve springs:
(1) Outer spring
Length under test force ... 35.8 mm (1.41 inch)
Test force ... 176 to 195 N (40 to 44 lb)
(2) Inner spring
Length under test force ... 34.0 mm (1.34 inch)
Test force ... 89 to 104 N (20 to 23 lb)
Single valve springs (not shown)
Length under test force ... 40.0 mm (1.57 inch)
Test force ... 310 to 344 N (70 to 77 lb)
Free length after test ... 53.4 mm (2.10 inch)
(3) Valve spring recess for the valve spring
(4) Valve guides for the inlet and exhaust valves
Inside diameter ... 9.51 to 9.56 mm (0.374 to 0.376 inch)
Outside diameter ... 15.900 to 15.910 mm (0.6260 to 0.6265 inch)
Bore diameter in cylinder head for valve guide ... 15.87 to 15.89 mm (0.625 to
0.626 inch)
Interference fit of valve guide in cylinder head ... 0.03 to 0.07 mm (0.001 to
0.003 inch)
Overall length of valve guide
Inlet ... 57.94 mm (2.281 inch)
Exhaust ... 61.1 mm (2.406 inch)
Projection of valve guide above valve spring recess (3) ... 15.1 mm (0.595 inch)
Note: When new valve guides are installed, new valves and new valve seat inserts must
be installed. The valve guides and the valve seat inserts are supplied as partially finished
parts. The unfinished valve guides and unfinished valve seat inserts are installed in the
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.
(5) Diameter of the exhaust valve stem ... 9.43 to 9.46 mm (0.371 to 0.372 inch)
Clearance of valve in valve guide ... 0.05 to 0.13 mm (0.002 to 0.005 inch)
Maximum permissible clearance of valve in valve guide ... 0.15 mm (0.006 inch)
Overall length of the exhaust valve ... 123.07 to 123.57 mm (4.845 to 4.865 inch)
(6) Diameter of the inlet valve stem ... 9.460 to 9.490 mm (0.3724 to 0.3735 inch)
Clearance of valve in the valve guide ... 0.02 to 0.10 mm (0.001 to 0.004 inch)
Maximum permissible clearance of valve in valve guide ... 0.13 mm (0.005 inch)
Overall length of the inlet valve ... 122.66 to 123.07 mm (4.829 to 4.845 inch)
(7) Exhaust valve face angle ... 45 degrees
Valve seat angle ... 46 degrees
(8) Diameter of the exhaust valve ... 37.26 to 37.52 mm (1.467 to 1.477 inch)
Valve depth below the cylinder head face
Minimum ... 1.28 mm (0.050 inch)
Maximum ... 1.83 mm (0.072 inch)
Service wear limit ... 2.08 mm (0.082 inch)
(9) Diameter of the inlet valve ... 44.86 to 45.11 mm (1.766 to 1.776 inch)
Valve depth below the cylinder head face
Minimum ... 1.27 mm (0.050 inch)
Maximum ... 1.60 mm (0.063 inch)
Service wear limit ... 1.85 mm (0.073 inch)
(10) 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)
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g00295327
Illustration 2
Recess for a valve insert
(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.
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Illustration 3
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
(12) Valve seat insert
(D) Included angle of the faces of the valve seat insert
Engines with 46 degree valve seats ... 88 degrees
Engines with 31 degree valve seats ... 118 degrees
(E) Dimension of chamfer for all engines ... 1.10 ± 0.20 mm (0.043 ± 0.008 inch)
(F) Angle of chamfer from the vertical for all engines ... 30 degrees
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.
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g00294082
Illustration 4
Inlet valves and exhaust valves
(1) Single valve springs
Length under test force ... 39.0 mm (1.54 inch)
Test force ... 246 to 277 N (55 to 62 lb)
(2) Valve spring insert for the valve spring
(3) Valve guides
Inside diameter of finished valve guide ... 9.00 to 9.02 mm (0.354 to 0.355 inch)
Outside diameter of inlet valve ... 13.03 to 13.05 mm (0.513 to 0.514 inch)
Outside diameter of exhaust valve ... 14.03 to 14.05 mm (0.552 to 0.553 inch)
Bore diameter in the cylinder head for the inlet valve guide ... 13.00 to 13.03
mm (0.512 to 0.513 inch)
Bore diameter in the cylinder head for the exhaust valve guide ... 14.000 to
14.027 mm (0.5512 to 0.5522 inch)
Interference fit of valve guide in the cylinder head ... 0.007 to 0.047 mm (0.0003
to 0.0019 inch)
Overall length of inlet and exhaust valve guides ... 51.25 mm (2.012 inch)
Projection of valve guide above the valve spring recess (2) ... 14.85 to 15.15 mm
(0.585 to 0.596 inch)
Note: When new valve guides are installed, new valves and new valve seat inserts must
be installed. The valve guides and the valve seat inserts are supplied as partially finished
parts. The unfinished valve guides and unfinished valve seat inserts are installed in the
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
g00295327
Illustration 5
Recess for a valve insert
(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
(12) Valve seat insert
(D) Included angle of the faces of the valve seat insert
Engines with 46 degree valve seats ... 88 degrees
Engines with 31 degree valve seats ... 118 degrees
(E) Dimension of chamfer for all engines ... 1.10 ± 0.20 mm (0.043 ± 0.008 inch)
1
(F) Angle of chamfer from the vertical for all engines ... 30 degrees
1 0
Cylinder Head
SMCS - 1100
g00295370
Illustration 1
Bolt tightening sequence for the cylinder head
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 N·m (81 lb ft)
2. Tighten bolts (1) through bolts (22) again in a numerical sequence.
Torque for bolts ... 110 N·m (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
b. Tighten the bolts of medium length "M" to the following value.
Rotate the bolts in a clockwise direction: ... 180 degrees
c. Tighten the bolts of long length "L" to the following value.
Rotate the bolts in a clockwise direction: ... 210 degrees
Ver imagen
g00295371
Illustration 2
Bolts, nuts, and components of the cylinder head
(1) Tighten the nuts that hold fuel injectors to the following torque: ... 12 N·m (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 N·m (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 N·m (55 lb ft)
Aluminum bracket ... 40 N·m (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
g00295372
Illustration 3
Positions for measuring the bow of the cylinder head (typical example)
Maximum permissible amount of bow (curve of cylinder head)
Naturally aspirated engines
A ... 0.08 mm (.003 inch)
B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Turbocharged engines
A ... 0.13 mm (.005 inch)
B ... 0.25 mm (.010 inch)
C ... 0.25 mm (.010 inch)
Tighten the bolts of the inlet manifold (not shown) to the following torque: ... 44 N·m
(32 lb ft)
Tighten exhaust manifold nuts (not shown) to the following torque:
Plated ... 44 N·m (32 lb ft)
Plain ... 50 N·m (37 lb ft)
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
g00295370
Illustration 4
Bolt tightening sequence for the cylinder head
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 N·m (81 lb ft)
2. Tighten bolts (1) through bolts (22) again in a numerical sequence.
Torque for bolts ... 110 N·m (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
b. Tighten the bolts of medium length "M" to the following value.
Rotate the bolts in a clockwise direction: ... 180 degrees
c. Tighten the bolts of long length "L" to the following value.
Rotate the bolts in a clockwise direction: ... 210 degrees
Ver imagen
g00295373
Illustration 5
Bolts, nuts, and components of the cylinder head
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 N·m (55 lb ft)
Aluminum bracket ... 40 N·m (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)
Maximum permissible amount of bow (curve of the cylinder head)
A ... 0.08 mm (.003 inch)
B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Tighten the bolts for the inlet manifold (not shown) to the following torque: ... 44 N·m
(32 lb ft)
Tighten the nuts for the exhaust manifold (not shown) to the following torque:
Plated ... 44 N·m (32 lb ft)
Plain ... 50 N·m (37 lb ft)
1 1 0
Turbocharger
SMCS - 1052
Turbocharger
Ver imagen
g00295466
Illustration 1
(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 N·m (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
N·m (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 N·m
(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 N·m (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
Bore inside diameter (maximum) ... 6.353 mm (.2501 inch)
(8) Backplate assembly
Seal inside diameter (maximum) ... 12.713 mm (.5005 inch)
Flatness from the backplate to the mating surface of the center housing is within
the following value: ... .013 mm (.0005 inch)
(9) Thrust collar
Thickness (maximum) ... 18.339 mm (0.7220 inch)
Bore inside diameter (maximum) ... 6.363 mm (.2505 inch)
Thrust bearing groove width (maximum) ... 4.440 mm (.1748 inch)
Thrust bearing groove diameter (minimum) ... 9.398 mm (.3700 inch)
Piston ring groove width (maximum) ... 1.659 mm (.0653 inch)
(10) Thrust bearing
Thickness (minimum) ... 4.359 mm (0.1716 inch)
Bore inside diameter (maximum) ... 10.922 mm (.4300 inch)
(11) Radial play (side to side movement) for shaft
Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)
Maximum permissible radial play (side to side movement) ... .15 mm (.0059
inch)
(12) Center housing
Bearing inside diameter (maximum) ... 15.806 mm (.6223 inch)
Seal inside diameter (maximum) ... 17.805 mm (.7010 inch)
Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
turbocharger to the manifold (not shown), to the following torque: ... 55 ± 5 N·m (40 ±
4 lb ft)
Air Inlet Heater
Ver imagen
g00298861
Illustration 2
(1) Electrical connection
(2) Fuel inlet
(3) Ball valve
(4) Valve holder
(5) Wire coil
(6) Ignition coil
Voltage ... 12 volts
Current draw ... 13.5 amperes
Tighten the air inlet heater to the inlet manifold to the following torque: ... 31 ± 8 N·m
1 1 0
(23 ± 6 lb ft)
Exhaust Manifold
SMCS - 1059
g00559857
Illustration 1
The cylinder head is shown.
Refer to Illustration 1 for the tightening sequence. Tighten the plated nuts for the
exhaust manifold to the following torque. ... 44 N·m (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 N·m (37 lb ft)
Type 2 Engines and 7BJ Engines
Ver imagen
g00501179
Illustration 2
Muffler
SMCS - 1062
Ver imagen
Illustration 1 g00295475
(1) Tighten the nuts to the following torque. ... 30 ± 7 N·m (22 ± 5 lb ft)
(2) Tighten the bolts and the nuts to the following torque. ... 55 ± 10 N·m (41 ± 7 lb ft
Camshaft
SMCS - 1210
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
Service Limit
Camshaft Journal Standard Diameter
Diameter (1)
1
50.710 to 50.740 mm (1.9965 to
50.660 mm (1.9945 inch)
1.9975 inch)
Ver imagen
g00295323
Illustration 2
Ver imagen
g00308804
Illustration 1
g00295480
Illustration 1
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)
1
(4) Tighten the bolt to the following torque: ... 44 ± 5 N·m (32 ± 4 lb ft)
1 0
Ver imagen
g00295506
Illustration 1
Oil pump cover
(1) Bolt
Tighten the cover bolts to the following torque: ... 28 N·m (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 N·m (16 lb ft)
Type ... Gerotor pump
Number of lobes
Inner rotor ... 6
Outer rotor ... 7
Ver imagen
g00295515
Illustration 2
Clearance for the outer rotor body
Clearance of the outer rotor to the body
The balancer unit is not installed. ... 0.15 to 0.34 mm (0.006 to 0.013 inch)
The balancer unit is installed. ... 0.31 to 0.45 mm (0.012 to 0.018 inch)
Ver imagen
g00295516
Illustration 3
Clearance for the inner rotor body
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
1 1 0
following torque: ... 22 N·m (16 lb ft)
/sisw eb/sisw eb/m i00676566
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
1 1
the following torque: ... 7 to 12 N·m (62 to 107 lb in)
0
Ver imagen
g00877006
Illustration 1
Water Pump
SMCS - 1361
Ver imagen
g00295544
Illustration 1
(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)
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.
Note: The water pump for Type 2 engines and 7BJ engines is not serviceable. Contact
1 1
your Caterpillar dealer for more replacement information.
0
Cylinder Block
SMCS - 1201
Ver imagen
g00892504
Illustration 1
Typical example
(1) Cylinder liner
Outside diameter of cylinder liner ... 104.25 to 104.28 mm (4.105 to 4.106 inch)
Inside diameter of cylinder liner ... 100.00 to 100.03 mm (3.937 to 3.938 inch)
Maximum permissible wear of cylinder liner bore ... 0.25 mm (0.010 inch)
Interference fit of cylinder liner in cylinder block ... 0.03 to 0.08 mm (0.001 to
0.003 inch)
Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 inch)
The projection of the liner flange can be 0.10 mm (0.004 inch) above to 0.10 mm (0.004
inch) below the top face of the cylinder block.
(2) Plug with baffle plates (if equipped)
Orientation of baffle plates to the vertical plane ... +/- 5 degrees
Depth of plug from face of cylinder block ... 3 mm (0.12 inch)
(3) Cylinder block
Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to
4.104 inch)
Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to
0.154 inch)
Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm
(4.245 to 4.250 inch)
(4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder
block to the following torque. ... 22 N·m (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 N·m (10 lb ft)
M8 ... 22 N·m (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 N·m (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 N·m (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)
Piston Cooling Jets (If Equipped)
Ver imagen
g00631670
Illustration 2
(1) Tighten the piston cooling jets to the following torque. ... 27 N·m (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 1 0
Crankshaft
SMCS - 1201
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
g00295557
Illustration 1
Crankshaft and main bearing journals
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)
Maximum permissible end play ... 0.51 mm (0.020 inch)
(6) Width of the connecting rod journal ... 40.35 to 40.42 mm (1.589 to 1.591 inch)
Connecting rod journal diameter of flange ... 133.27 to 133.37 mm (5.247 to 5.251 inch)
Depth of recess for connecting rod bearing ... 20.22 to 20.98 mm (0.796 to 0.826 inch)
Bore of recess for connecting rod bearing ... 46.96 to 46.99 mm (1.849 to 1.850 inch)
Measure the connecting rod journals on the crankshaft. See the following chart for the
dimensions.
Table 1
Connecting Rod Bearing Journal
If the bearing journal has been ground beyond this size, then
regrind the bearing journals to the next undersize journal. 63.43 mm (2.497 inch)
Original Size Journal
63.47 to 63.49 mm
(2.499 to 2.500 inch)
Undersize Journal
0.25 mm (0.010 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. 76.12 mm (2.996 inch)
Original Size Journal
76.16 to 76.18 mm
(2.998 to 2.999 inch)
Undersize Journal
0.25 mm (0.010 inch) 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 N·m (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 N·m (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 N·m (26 lb ft)
M12 bolts ... 75 N·m (55 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the cylinder block (not shown)
to the following torque: ... 22 N·m (16 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the bridge (not shown) to the
following torque:
M6 ... 13 N·m (10 lb ft)
M8 ... 18 N·m (13 lb ft)
1 1 0
Crankshaft Seals
SMCS - 1160; 1161
Ver imagen
g00664588
Illustration 1
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 N·m (85
lb ft)
Crankshaft Rear Seal
Engines with 14 Bolt Housing Assembly
Ver imagen
g00317365
Illustration 2
Connecting Rod
SMCS - 1218
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
g00295602
Illustration 1
Ver imagen
g00915056
Illustration 2
Table 1
"F" Red
165.728 to 165.761 mm (6.5247 to 6.5265 inch)
"G" Orange
165.682 to 165.715 mm (6.5229 to 6.5247 inch)
"H" White
165.637 to 165.670 mm (6.5211 to 6.5229 inch)
"J" Green
165.591 to 165.624 mm (6.5193 to 6.5211 inch)
"K" Purple
165.545 to 165.578 mm (6.5175 to 6.5193 inch)
"L" Blue
165.499 to 165.532 mm (6.5157 to 6.5175 inch)
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:
Determine the length of the connecting rod.
Determine the distortion of a connecting rod.
Replace the piston pin bearing.
Turbocharged Engines
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Illustration 3
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Illustration 4
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Illustration 5
(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
/sisw eb/sisw eb/m /sisw eb/mediase
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Illustration 1
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Illustration 2
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)
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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
A (1) G
70.334 mm (2.7690 inch)
B (1) H
70.289 mm (2.7673 inch)
C (1) J
70.244 mm (2.7655 inch)
D (1) K
70.199 mm (2.7637 inch)
E (1) L
70.154 mm (2.7620 inch)
F -
70.391 mm (2.7713 inch)
G -
70.345 mm (2.7695 inch)
H -
70.299 mm (2.7677 inch)
J -
70.253 mm (2.7659 inch)
K -
70.207 mm (2.7640 inch)
L -
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.
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Illustration 4
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
(1) Top piston ring
Shape of groove in piston for top ring ... Taper
Clearance between the ends of the top ring in a cylinder liner without any wear ... 0.28
to 0.63 mm (.011 to .025 inch)
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)
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)
1 1 0
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
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Illustration 1
Front housing and front cover
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Illustration 2
9U-6200 Front Cover Installer
(1) Front cover
The front cover must be centered on the front of the engine before the bolts are
tightened. Use a 9U-6200 Front Cover Installer to center the front cover before the bolts
are tightened.
(2) Front housing
Tighten the M8 bolts (not shown) that fasten the front housing to the cylinder
block to the following torque: ... 22 N·m (16 lb ft)
Tighten the M10 bolts (not shown) that fasten the front housing to the cylinder
block to the following torque: ... 44 N·m (33 lb ft)
(3) Bolts
After the front cover is centered on the front of the engine, tighten the bolts and
the two nuts that fasten the front cover to the front housing. Tighten the bolts
and the nuts to the following torque: ... 22 N·m (16 lb ft)
(4) 9U-6200 Front Cover Installer
The front cover installer is used to center the front cover on the front of the engine.
Refer to the Disassembly and Assembly Module, "Front Cover - Install" topic for
1 1 0
additional information.
Gear Group (Front)
SMCS - 1206
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Illustration 1
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Illustration 1
(1) Tighten the bolts of the flywheel housing to the following torque:
The M10 bolts for the cast iron flywheel housing ... 44 N·m (32 lb ft)
The M12 bolts that are stamped "8.8" for the cast iron flywheel housing ... 75 N·m (55
lb ft)
The M10 bolts that are stamped "10.9" for the cast iron flywheel housing ... 63 N·m (46
lb ft)
The M12 bolts that are stamped "10.9" for the cast iron flywheel housing ... 115 N·m
(85 lb ft)
The M10 bolts that are for the aluminum flywheel housing ... 70 N·m (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 N·m (77 lb ft)
Flywheel Housing Runout
Face Runout
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Illustration 2
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Illustration 3
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Illustration 4
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Illustration 5
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Illustration 1
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Illustration 2
End view of the starting motor which shows the electrical connections
No load conditions at 25 °C (77 °F)
Rpm of shaft ... 7000 minimum
(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 N·m (18 to 24 lb
ft)
(2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 N·m (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
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Illustration 3
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Illustration 4
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