Specif - CAT 3612 PDF

RENR5907
October 2001
Specifications
G3612 and G3616 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
i01097883
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.
Caterpillar 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 Caterpillar 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. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar 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.
3
Table of Contents
Table of Contents Pressure Switch ....................................................

Pressure Switch (Hydrax) .....................................
53
54
Prelube Pressure Switch ...................................... 54
Pressure Sensor ................................................... 54
Specifications Section Pressure Sensor ................................................... 55
Pressure Sensor ................................................... 55
Engine Design ....................................................... 4
Temperature Sensor ............................................. 55
Engine Design ....................................................... 4
Detonation Sensor ................................................ 55
Air Lines (Choke) .................................................... 5
Engine Speed/Timing Sensor ............................... 56
Gas Engine Ignition ............................................... 6
Electrohydraulic Actuator ........................................ 7
Electronic Control (Combustion Sensor) ................ 7 Index Section
Fuel Control ............................................................ 8
Fuel Lines ............................................................... 9 Index ..................................................................... 57
Camshaft ............................................................... 9
Valve Mechanism ................................................. 11
Cylinder Head, Valves, Valve Springs and Valve Seat
Inserts ................................................................. 13
Turbocharger ........................................................ 16
Exhaust Manifold ................................................. 17
Exhaust Bypass Valve ......................................... 18
Aftercooler ........................................................... 20
Air Cleaner Adapter .............................................. 20
Prelube Pump ....................................................... 20
Engine Oil Pump .................................................. 21
Priority Valve ........................................................ 22
Engine Centrifugal Oil Filter .................................. 23
Engine Oil Filter ................................................... 23
Engine Oil Cooler ................................................. 23
Engine Oil Temperature Regulator ....................... 23
Crankcase Breather ............................................. 24
Water Pump ......................................................... 25
Water Temperature Regulator .............................. 27
Cylinder Block ...................................................... 28
Crankshaft ........................................................... 30
Crankshaft Seals ................................................. 32
Connecting Rod ................................................... 32
Connecting Rod and Main Bearing Journals ........ 34
Piston and Rings .................................................. 34
Cylinder Liner ....................................................... 35
Camshaft Bearings .............................................. 36
Camshaft Bearing Position .................................. 37
Camshaft Bearing Position .................................. 39
Gear Group (Front) ............................................... 40
Housing (Front) ..................................................... 41
Gear Group (Rear) ................................................ 42
Housing (Rear) ..................................................... 44
Vibration Damper (Dual) ....................................... 45
Vibration Damper (Single) .................................... 46
Flywheel ............................................................... 47
Flexible Coupling .................................................. 48
Flexible Drive ........................................................ 48
Manual Barring Group (Air Interlock) .................... 49
Engine Lifting Bracket ........................................... 49
Engine Support .................................................... 49
Belt Tension Chart ............................................... 49
Accessory Drive ................................................... 51
Alternator and Regulator ...................................... 52
Air Starting Motor ................................................. 53
Air Starting Motor Pressure Regulating Valve ..... 53
4
Specifications Section
Specifications Section When the crankshaft is viewed from the flywheel

end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
i01530807
Note: The front end of the engine is opposite
Engine Design the flywheel end of the engine. The left and the
right side of the engine are determined from the
SMCS Code: 1000; 1201 flywheel end. The number 1 cylinder is the right
front cylinder.
S/N: BKE1-Up
i01559289
Engine Design
SMCS Code: 1000; 1201
S/N: BLB1-Up
g00471973
Illustration 1
Engine Design
(A) Inlet valves. (B) Gas admission valves. (C) Exhaust valves.
Number and arrangement of cylinders ......... Vee 12
Valves per cylinder

g00472128
Illustration 2
Inlet valves ....................................................... 2
Engine Design
Exhaust valves ................................................. 2 (A) Inlet valves. (B) Gas admission valves. (C) Exhaust valves.
Gas admission valve ........................................ 1 Number and arrangement of cylinders ......... Vee 16
3
Displacement ........................... 254.5 L (15,525 in ) Valves per cylinder
Bore .......................................... 300 mm (11.8 inch) Inlet valves ....................................................... 2
Stroke ........................................ 300 mm (11.8 inch) Exhaust valves ................................................. 2

Gas admission valve ........................................ 1
Compression ratio ............................................... 9:1
Displacement ........................... 339.3 L (20,700 in 3 )
Combustion ........................................ Spark Ignited
Bore .......................................... 300 mm (11.8 inch)
Firing order
Standard rotation Stroke ........................................ 300 mm (11.8 inch)
CCW ........................ 1-12-9-4-5-8-11-2-3-10-7-6
Compression ratio ............................................... 9:1
Valve lash
Combustion ........................................ Spark Ignited
Inlet valve .......................... 0.50 mm (.020 inch)
Firing order
Exhaust valve .................... 1.27 mm (.050 inch)
Standard rotation
Gas admission valve ......... 0.64 mm (.025 inch) CCW ... 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8
Valve lash
5
Inlet valve .......................... 0.50 mm (.020 inch) Thickness of thrust washer ...... 6.00 ± 0.05 mm
(0.236 ± 0.002 inch)
Exhaust valve .................... 1.27 mm (.050 inch)
(4) Housing
Gas admission valve ......... 0.64 mm (.025 inch)
Bore in housing for shaft
When the crankshaft is viewed from the flywheel bearings ............................. 25.402 ± 0.010 mm
end the crankshaft rotates in the following (1.0001 ± 0.0004 inch)
direction. ....................................... Counterclockwise Outside diameter of shaft
bearings ............................... 25.529 ±0.020 mm
Note: The front end of the engine is opposite (1.0051 ± 0.0008 inch)
the flywheel end of the engine. The left and the
right side of the engine are determined from the Assemble the choke and the actuator linkage by
flywheel end. The number 1 cylinder is the right using the following procedure.
front cylinder.
Note: Install bearings (8) so the lube fitting is
i01541018
accessible. Lubricate the bearings with 5P-0960
Lithium complex grease.
Air Lines
1. Assemble choke plate (6) to shaft (5). Leave the
(Choke) mounting bolts loose. Assemble thrust washer
(3) onto the shaft. Install cover assembly (2).
SMCS Code: 1058
Width of groove in shaft for thrust
washer .. 6.53 ± 0.10 mm (0.2571 ± 0.0039 inch)
Thickness of thrust washer ........ 6.00 ± 0.08 mm

(0.2362 ± 0.0031 inch)
Tighten the bolts for the thrust washer to the

following torque. .......... 47 ± 9 N·m (35 ± 7 lb ft)
Tighten the bolts for the cover assembly to the

2. Hold the plate in the fully closed position and

tighten mounting bolts (7) for the plate.
Tighten the mounting bolts. ............... 12 ± 3 N·m

(9 ± 2 lb ft)
3. Hold the plate in the closed position. Tighten

adjusting bolt (1) until the adjusting bolt makes
contact with the stop plate. Tighten the adjusting
bolt for an additional 1/4 turn.
Tighten the locking nut to the following

torque. .......................... 25 ± 6 N·m (18 ± 4 lb ft)
Note: Do not allow the adjusting bolt to turn while

g00800645 the locking nut is tightened.
Illustration 3
Rear View
(1) Adjusting bolt
(2) Cover assembly
(3) Thrust washer

Width of groove in shaft for thrust
washer ...................................... 6.53 ± 0.10 mm
(0.2571 ± 0.0039 inch)
6
Tighten connecting rod end nuts (11) to the

following torque. ............... 25 ± 6 N·m (18 ± 4 lb ft)
i01574790
Gas Engine Ignition

SMCS Code: 1550
g00804832
Illustration 4
Closed Position
1. Install actuator (12) so inlet port (13) and outlet

port (14) are aligned. This is shown in Illustration
g00818389
4. The ports on the actuator are stamped “Inlet” Illustration 5
and “Outlet”. With the choke plate in the fully
closed position, the actuator lever should be at (1) Transformer assembly
an angle (A) of 27 degrees.
(2) Seals
2. Assemble connecting rod (10) so that there is
equal thread engagement at each end. With Lubricate the bore lightly with engine oil.
the choke plate in the fully closed position,
assemble the choke side lever at an angle (B) of (3) Extension assembly
45 degrees. Assemble the actuator side lever at
an angle of 34 degrees. (4) Spark plug
Tighten the bolts for the levers to the following Tighten the spark plug in the cylinder head to
torque. .......................... 47 ± 9 N·m (35 ± 7 lb ft) the following torque. ... 68 ± 4 N·m (50 ± 3 lb ft)
Spark plug gap ........................ 0.29 ± 0.04 mm
Tighten the bolts that hold the levers (0.011 ± 0.002 inch)
to the connecting rods to the following
torque. .......................... 47 ± 9 N·m (35 ± 7 lb ft) Note: A new gasket should be used when a spark
plug is installed. Install the spark plug gasket with
Note: A final adjustment of the linkage is required the tangs toward the sealing face of the spark plug.
to ensure that the actuator does not try to force
the plate past the full open stop when the actuator Tighten the nuts for the connectors to the
is in the open position. Fully extend the actuator transformers in a clockwise motion. Use 6V-0006
to the full open position. With the plate in contact Electrical Connector Pliers to tighten the nuts.
with the full open stop, shorten the length of the
connecting rod by 1/2 turn. This will create a small
gap between the two full open stop plates. Lock the
connecting rod in place. Ensure that the plate can
still reach the full closed stop.
Tighten rod end nuts (9) for the actuator to the

following torque. ............... 25 ± 6 N·m (18 ± 4 lb ft)
7
i01608517 i01552686
Electrohydraulic Actuator Electronic Control

SMCS Code: 1716
(Combustion Sensor)
SMCS Code: 1559
g00833105
Illustration 6
(1) Piston assembly
(2) Housing
1. Insert the piston assembly into the housing.
Torque .................... 125 ± 15 N·m (92 ± 11 lb ft) g00807399

Illustration 7
(3) Plug (1) Extension
Torque ............................... 27 ± 5 N·m (20 ± 4 lb ft) (2) Combustion sensor
(4) Bolts Tighten the combustion sensor to the following

torque. ........................ 38 ± 2 N·m (28 ± 1 lb ft)
Finger tighten the bolts. Torque ............ 3 ± 0.2 N·m
(27 ± 2 lb in)
8
i01549434 Assemble connecting rod (7) so that there is equal

thread engagement at each end. Adjust the rod to
Fuel Control the correct distance.
SMCS Code: 1550 Distance (D) . .............. 234.2 mm (9.2205 inch)
Tighten rod end nuts (9). ................. 25 ± 6 N·m
(18 ± 4 lb ft)
Tighten end bolts (8). .. 47 ± 9 N·m (35 ± 7 lb ft)
Tighten bolt (6). .......... 47 ± 9 N·m (35 ± 7 lb ft)
When the fuel valve is in the closed position the

actuator lever should be at angle (A) and the
distance from the clevis to the mounting plate
should be length (B).
Angle (A). ........................................... 9 degrees
Length (B). .................. 138.8 mm (5.4646 inch)
When the fuel valve is in the open position the

actuator lever should be at angle (C) and the
distance from the clevis to the mounting plate
should be length (E).
Angle (C). ......................................... 36 degrees
Length (E). ..................... 90.9 mm (3.5787 inch)
g00805470
Illustration 8
Top View
Install bearings (4) so the lube fitting is accessible.

Lubricate the bearings with 5P-0960 Lithium
complex grease.
Tighten bolts for the bearings. ......... 47 ± 9 N·m
(35 ± 7 lb ft)
Install actuator (1) so the inlet port and the outlet

port are aligned. This is shown in illustration 8. The
ports on the actuator are stamped “Inlet” (2) and
“Outlet” (3).
Tighten the nut for the actuator. ... 200 ± 20 N·m
(148 ± 15 lb ft)
g00806072
Illustration 10
Fuel Control Linkage
Assemble connecting rod (12) so that there is equal

thread engagement at each end. Adjust the rod to
the correct distance.
Distance (H). .................. 172 mm (6.7716 inch)
Tighten rod end nuts (13). ............... 25 ± 6 N·m
(18 ± 4 lb ft)
Tighten end bolts (11). ..................... 47 ± 9 N·m
(35 ± 7 lb ft)
g00806071
Illustration 9 Tighten bolt (10). ........ 47 ± 9 N·m (35 ± 7 lb ft)
Fuel Control Actuator
9
When the fuel valve is in the closed position the (4) Fuel line
lever should be at angle (F) and the distance from
the connecting rod to the fuel valve should be
length (J).
Angle (E). ......................................... 26 degrees
Length (H). .................... 40.7 mm (1.6024 inch)
When the fuel valve is in the open position the lever

should be at angle (G) and the distance from the
connecting rod to the fuel valve should be length
(K).
Angle (F). .......................................... 71 degrees
Length (J). ................... 159.7 mm (6.2874 inch)
A final adjustment of the linkage is required to g00480001

Illustration 12
ensure that the actuator is not over rotating the
valve stem when the fuel valve is in the closed (5) Needle valve
position. The actuator must still close the fuel valve.
Note: Direction of arrow on the needle valve should
1. Fully extend the actuator and close the fuel valve. point toward the cylinder head.
2. Rotate the clevis by 1/2 turn so that the clevis
Refer to the Testing and Adjusting for the procedure
moves away from the metering valve. to adjust the needle valves.
3. Lock the linkage into position and ensure that
the metering valve will still reach the full open i00945755
position.
Camshaft
i00941477 SMCS Code: 1210
Fuel Lines
SMCS Code: 1550
g00482459
Illustration 13
(1) Thickness of new thrust plate .. 15.00 ± 0.25 mm

(.591 ± .010 inch)
(2) Diameter of camshaft

journal ... 173.80 ± 0.03 mm (6.843 ± .001 inch)
Bore in camshaft bearing after

installation ... 174.00 ± 0.06 mm (6.850 ± .002 inch)
g00479970
Illustration 11
(3) Thickness of new plate .......... 11.80 ± 0.05 mm
(1) Fuel control linkage (.465 ± .002 inch)
(2) Tube assembly (4) Timing bolt location
(3) Fuel control valve

10
NOTICE
Correct cam segment relationship (timing) must be ob-
served at assembly. If the cam segments are out of
time, serious engine damage will occur.
g00482541
Illustration 16
Letter Designation Of G3612 Camshaft Journals
g00289768
Illustration 14
Location Of The Dowels On The Camshaft Bearing Journals
g00482543
Illustration 17
Letter Designation Of G3616 Camshaft Journals
(8) Camshaft bearing journal
g00482542 Install the camshaft bearing journals with the

Illustration 15 grooved end toward the front of the engine.
Location Of The Dowels On The Camshaft Bearing Journals
(9) Camshaft segments
Note: The position of the single dowel in relation to
the variable dowel determines the letter designation Install the camshaft segments with the grooved
of the cam journals. The single dowel is located flange toward the front of the engine.
next to the locating groove. The variable dowel is
on the end opposite the locating groove. (10) Tighten the bolts for the camshaft segment to
the following torque. ..................... 270 ± 40 N·m
(5) Locating groove (200 ± 30 lb ft)
(6) Location of the single dowel in the face of the (11) The camshaft must be assembled in an
camshaft bearing journal assembly fixture or the camshaft must be
assembled in the cylinder block.
Distance from the top of the dowel to the
camshaft bearing journal ............. 7.0 ± 0.5 mm Apply a force at the rear end of the camshaft
(.28 ± .02 inch) (11). The rolling torque must be a maximum of
the following value. ................. 28 N·m (21 lb ft)
(7) Location of the variable dowel in the face of the
camshaft bearing journal
Distance from the top of the dowel to the
camshaft bearing journal ............. 7.0 ± 0.5 mm
(.28 ± .02 inch)
11
i01532351
Valve Mechanism
SMCS Code: 1102; 1121; 1209
g00289772
Illustration 18
(12) Specified camshaft lobe lift
To find the specified camshaft lobe lift, use the

procedure that follows:
1. Measure the total height of the camshaft (13).
2. Measure base circle (14).
3. Subtract base circle (14) from the total height of g00284769

Illustration 19
camshaft (13). The difference is the specified
camshaft lobe lift (12).
(1) Tighten the rocker arm adjustment screw
locknut. ............... 200 ± 25 N·m (150 ± 18 lb ft)
4. Specified camshaft lobe lift (12) for the camshaft
is the following value:
(2) The diameter of the rocker arm shaft is the
following value. ................... 69.900 ± 0.015 mm
Exhaust lobe ................. 19.500 mm (.7677 inch)
(2.7520 ± 0.0006 inch)
Inlet lobe ....................... 19.500 mm (.7677 inch)
The bore in the bearings for the rocker arm shaft is
the following value. ................... 70.000 ± 0.015 mm
Gas admission lobe ...... 10.001 mm (.3937 inch)
(2.7559 ± 0.0006 inch)
(3) Valve lash

Inlet valve ........................ 0.50 mm (0.020 inch)
Exhaust valve .................. 1.27 mm (0.050 inch)
Gas admission valve ....... 0.64 mm (0.025 inch)
(4) Tighten the bridge adjustment screw locknut to

(75 ± 11 lb ft)
(5) Diameter of bridge dowel .. 19.055 ± 0.003 mm

(0.7502 ± 0.0001 inch)
Diameter of bore in bridge ....... 19.162 ± 0.030 mm

(0.7544 ± 0.0012 inch)
Diameter of bore in plug for

dowel .. 19.017 ± 0.020 mm (0.7487 ± 0.0008 inch)
Diameter of plug ....................... 27.050 ± 0.008 mm

(1.0650 ± 0.0003 inch)
12
Diameter of bore in cylinder head for

plug ..... 27.000 ± 0.020 mm (1.0630 ± 0.0008 inch)
(6) Support assembly and the gas admission valve
(7) The guide springs must not be used again.

Always install new guide springs.
g00285522
Illustration 21
(12) Tighten the bolts to the following

torque. ................ 430 ± 60 N·m (320 ± 44 lb ft)
g00795499
Illustration 20
(8) Guides for the lifters
(9) The diameter of the inlet and exhaust valve lifter

is the following value. ......... 41.910 ± 0.010 mm
(1.6500 ± 0.0004 inch)
The valve guide bore of the inlet and exhaust valve

lifter is the following value. ....... 42.000 ± 0.020 mm
(1.6535 ± 0.0008 inch)
(10) The diameter of the adapter of the lifter

for the gas admission valve is the following
value. .................................. 56.070 ± 0.020 mm
(2.2075 ± 0.0008 inch)
The bore in the guide for the adapter is the following

value. .. 56.000 ± 0.020 mm (2.2047 ± 0.0008 inch)
(11) The diameter of the lifter for the gas admission

valve is the following value. .. 27.896 ± 0.013 mm
(1.0983 ± 0.0005 inch)
The bore in the adapter of the lifter for

the gas admission valve is the following
value. .. 27.950 ± 0.020 mm (1.1004 ± 0.0008 inch)
13
i01538440
Cylinder Head, Valves, Valve

Springs and Valve Seat Inserts
SMCS Code: 1101; 1103; 1104; 1105; 1108; 1123
g00288893
Illustration 22
(1) Assembled height of rocker arm support Free length after test ....... 114.0 mm (4.49 inch)
dowels ............ 8.0 ± 1.0 mm (0.32 ± 0.04 inch) Outside diameter ............... 68.0 mm (2.68 inch)
(2) Inside diameter of assembled valve (6) Assembled height of valve

guides ................................. 16.031 ± 0.028 mm guides ........... 20.0 ± 2.0 mm (0.79 ± 0.08 inch)
(0.6311 ± 0.0011 inch)
(7) Procedure to tighten the cylinder head nuts
(3) Assembled height of bridge
dowels ........ 105.0 ± 2.0 mm (4.13 ± 0.08 inch) 1. Assemble the seals, the gasket and the washers
to the cylinder head. Tighten the nuts by hand.
(4) 1W-1749 Spring inner spring for valve
2. Use the 4C-5850 Stud Tensioner Tool Group to
Length under test force .... 79.3 mm (3.12 inch) apply tension to all four studs at the same time.
Test force ....................... 361 ± 36 N (80 ± 8 lb)
Free length after test ....... 107.0 mm (4.21 inch) Tension the studs to the following
Outside diameter ............... 47.9 mm (1.89 inch) value. ......... 40000 ± 1500 kPa (5800 ± 220 psi)
(5) 1W-1748 Spring outer spring for valve 3. Tighten the nuts by hand.
Length under test force .... 84.9 mm (3.34 inch)
4. Slowly release the pressure.
Test force ................... 758 ± 76 N (170 ± 17 lb)
14
5. Repeat Step 2 through Step 4. Diameter of exhaust valve

stem ...................................... 15.977 ± 0.01 mm
(8) Install the check valve assembly in the (0.6290 ± 0.0004 inch)
precombustion chamber. Tighten the
check valve assembly to the following Install the valve guide into the cylinder head.
torque. .................. 115 ± 15 N·m (85 ± 11 lb ft) The bore in the valve guide is the following
dimension. ................................ 16.031 ± 0.028 mm
Tighten the plug to the following torque. .. 45 ± 9 N·m (0.6311 ± 0.0011 inch)
(33 ± 7 lb ft)
Note: The inlet valve stems and the exhaust valve
(9) Angle of valve face stems should be coated with 8T-2998 Lubricant.
This should be prior to the installation in the cylinder
Angle of the face of the inlet head.
valve ................................ 20.25 ± 0.10 degrees
Angle of the face of the exhaust (13) Diameter of valve seat inserts
valve ................................ 20.25 ± 0.10 degrees
Diameter of inlet valve seat
(10) Thickness of combustion gasket .. 4 ± 0.05 mm insert ................................... 97.195 ± 0.015 mm
(0.158 ± 0.002 inch) (3.8266 ± 0.0006 inch)
Diameter of exhaust valve seat
Surfaces must be parallel within the following insert ................................... 97.215 ± 0.015 mm
dimension. ............................. 0.03 mm (0.001 inch) (3.8274 ± 0.0006 inch)
Bore in head for valve seat

inserts .. 97.000 ± 0.025 mm (3.8189 ± 0.0010 inch)
(14) Angle of face of valve seat

inserts ........................................ 20 ± 1 degrees
Contact is required between both the valve and the

insert for the full 360 degrees. This should be a full
face contact. The minimum width of the seat is the
following dimension. .................. 3.0 mm (0.12 inch)
(15) Maximum recess from the closed valve face to

the surface of the cylinder head ............ 2.0 mm
(0.08 inch)
Maximum projection of the closed valve above the

surface of the cylinder head .. 0.50 mm (0.020 inch)
(16) Outside diameter of the head of the inlet

valve ..... 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
Outside diameter of head of the exhaust

valve ........... 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
(17) The minimum valve lip thickness that

can be used again is the following
dimension. ....................... 5.40 mm (0.213 inch)
g00288894
Illustration 23
Inlet and exhaust valves
(11) Depth of bore for valve seat

insert ..... 24.00 ± 0.15 mm (0.945 ± 0.006 inch)
(12) Diameter of valve stems

Diameter of inlet valve
stem .................................... 15.980 ± 0.007 mm
(0.6291 ± 0.0003 inch)
15
(25) Outside diameter of the head of the gas

admission valve ...................... 41.81 ± 0.13 mm
(1.646 ± 0.005 inch)
g00832771
Illustration 24
Gas admission valve
(18) 7N-1904 Spring outer spring for valve

Test force ....................... 254 ± 25 N (57 ± 6 lb)
Free length after test ......... 62.5 mm (2.46 inch)
Outside diameter ............... 44.0 mm (1.73 inch)
(19) Valve stem seal
Note: To prevent contamination of the fuel supply,

install a valve stem seal on each gas admission
valve.
(20) 7N-1903 Spring inner spring for valve

Test force ....................... 125 ± 12 N (28 ± 3 lb)
Free length after test ......... 51.5 mm (2.03 inch)
(21) Inside diameter of the valve guide for the gas

admission valve .................... 9.502 ± 0.013 mm
(0.3741 ± 0.0005 inch)
(22) Install the retainer and tighten the retainer to

(75 ± 11 lb ft)
(23) Diameter of the valve stem for the gas

admission valve .................... 9.441 ± 0.008 mm
(0.3717 ± 0.0003 inch)
(24) Angle of the face of the gas admission

valve ................................ 45.75 ± 0.25 degrees
Angle of the support for the gas admission

valve ........................................ 44.75 ± 0.5 degrees
16
i01569582
Turbocharger
SMCS Code: 1052
g00815048
Illustration 25
(1) Torque for impeller retaining bolt ... 48 ± 12 N·m (8) Tighten the bolts to the following
(35 ± 9 lb ft) torque. ................... 12 ± 3 N·m (106 ± 27 lb in)
(2) Tighten the bolts to the following (9) Tighten the bolts to the following
torque. ...................... 50 ± 10 N·m (37 ± 7 lb ft) torque. ...................... 55 ± 10 N·m (41 ± 7 lb ft)
torque. ........................ 30 ± 7 N·m (22 ± 5 lb ft) torque. ........................ 15 ± 3 N·m (11 ± 2 lb ft)
torque. ........................ 28 ± 7 N·m (21 ± 5 lb ft) torque. ...................... 50 ± 10 N·m (37 ± 7 lb ft)
torque. ...................... 50 ± 10 N·m (37 ± 7 lb ft) torque. ...................... 55 ± 10 N·m (41 ± 7 lb ft)

torque. ........................ 30 ± 7 N·m (22 ± 5 lb ft)

torque. ...................... 55 ± 10 N·m (41 ± 7 lb ft)
17
i01545220
Exhaust Manifold
SMCS Code: 1059
g00802947
Illustration 26
Note: Assemble or disassemble the exhaust

manifold segments individually in order to avoid
damaging the bellows. The bolts with nuts may
be assembled from either side of the flange. Put
5P-3931 Anti-Seize Compound on all threads prior
to assembly.
Assemble the exhaust manifolds by using the

following procedure:
(1) Assemble the manifolds to the cylinder heads

hand tight.
(2) Assemble the bellows to the manifolds and to

the turbochargers.
(3) Tighten the bolts. ..... 50 ± 10 N·m (37 ± 7 lb ft)
(4) Tighten the bolts. ......................... 240 ± 40 N·m

(177 ± 30 lb ft)
(5) Tighten the bolts. .. 105 ± 20 N·m (77 ± 15 lb ft)
(6) Tighten the adapters. ................... 200 ± 25 N·m

(150 ± 18 lb ft)
(7) Install caps on the adapters.

18
i01546596
Exhaust Bypass Valve

SMCS Code: 1057
g00803694
Illustration 27
Right Side View
(1) Bolts Outside diameter of shaft

bushings ............................. 25.898 ± 0.013 mm
Put 5P-3931 Anti-Seize Compound on the (1.0196 ± 0.0005 inch)
threads of the bolts before assembly. Tighten Inside diameter of in-line shaft
the bolts to the following torque. .. 120 ± 20 N·m bushings ............................. 19.806 ± 0.013 mm
(89 ± 15 lb ft) (0.7798 ± 0.0005 inch)
Diameter of shaft ................ 19.500 ± 0.013 mm
(2) Tighten the nuts to the following (0.7677 ± 0.0005 inch)
torque. .................. 100 ± 20 N·m (74 ± 15 lb ft)
Use the following procedure in order to assemble
(3) Housing the wastegate and the actuator linkage.
Bore in housing for shaft
bushings ............................. 25.845 ± 0.013 mm 1. Assemble the plate of the wastegate to the shaft.
Leave the mounting bolts loose. Assemble thrust
(1.0175 ± 0.0005 inch)
washer (4) and axial stop (5).
19
Thickness of thrust washer ........ 6.00 ± 0.08 mm

(0.2362 ± 0.0031 inch)
Tighten the axial stop bolt to the following

torque. .......................... 47 ± 9 N·m (35 ± 7 lb ft)
2. Install cover (6).
Tighten the cover bolts to the following

torque. .......................... 47 ± 9 N·m (35 ± 7 lb ft)
3. Fully close the plate of wastegate (9).
Tighten mounting bolts (10) to the following

torque. .......................... 14 ± 3 N·m (10 ± 2 lb ft)
Bend the locking ends upward in order to secure

the bolts in position. Install spacer (7) and cover
assembly (8) onto the shaft. Make sure that the
shaft can rotate freely.
Tighten the bolts for the cover assembly to the

4. Put 5P-3931 Anti-Seize Compound on the

threads of bolts (11) before assembly.
Tighten the bolts to the following

g00804359
torque. ........................ 50 ± 10 N·m (37 ± 7 lb ft) Illustration 28
Actuator and Adjustable Rod Linkage
5. Install cross shaft (13) with the end that is Closed Position
stamped “W/G END” toward the housing of the
wastegate. 8. Assemble the levers to the shaft of the wastegate
and to the cross shaft. Use the woodruff keys in
6. Install bearings (16) so the lube fitting is order to provide proper orientation. Assemble
accessible. Lubricate the bearings with 5P-0960 upper connecting rod (12) so that there is equal
Lithium complex grease. thread engagement at each end. Adjust the rod
to the correct distance.
7. Install actuator (14) so the inlet port and outlet
port (15) are aligned. The ports on the actuator The distance between the rod ends of
are stamped “Inlet” and “Outlet”. the upper connecting rod is the following
value. ....... 640 ± 1 mm (25.1968 ± 0.0394 inch)
Tighten nuts (17) to the following

torque. .......................... 25 ± 6 N·m (18 ± 4 lb ft)
9. Assemble the lever on the side of the cross shaft

that goes toward the actuator. Use the woodruff
key to assemble the lever. Assemble the linkage
on the actuator. Check the distance between the
rod end and the clevis when the actuator is in
the extended position.
The distance between the rod end and the clevis

should be the following value. ....... 80.5 ± 1 mm
(3.1693 ± 0.0394 inch)
When the adjustable rod for the actuator is in the

closed position the lever should be at angle (A).
Angle (A). .................................... 45 degrees
20
When the adjustable rod is in the closed position i00652129

the levers should be at angle (B) and angle (C).
Air Cleaner Adapter
Angle (B). .................................... 45 degrees
Angle (C). .................................... 45 degrees SMCS Code: 1051
Note: A final adjustment of the linkage is required to

ensure that the plate does not contact the housing
when the plate is in the closed position. Fully extend
the actuator to the closed position. With the plate in
contact with the housing, shorten the length of the
connecting rod by 2/3 turn. Lock the connecting
rod in place.
i01570178
Aftercooler
SMCS Code: 1063
g00289587
Illustration 30
(1) Assemble the two tandem clamps in order to go

around the hose.
Maximum torque on clamp bolts ........... 10 N·m
(7 lb ft)
i01100343
Prelube Pump
SMCS Code: 1319
g00479750
Illustration 29
(1) The aftercooler core must withstand the

following water pressure. ........ 330 kPa (48 psi)
(2) Put a light coat of glycerin on all O-ring seals

at assembly.
(3) Put 9S-3263 Thread Lock Compound on the

threads of the bolts. Tighten the bolts that
hold the aftercooler to the cylinder head to the
following torque. ....... 50 ± 10 N·m (37 ± 7 lb ft)
g00288335
Illustration 31
(1) Inside diameter of idler gear

bearing ...................... 19.126 mm (0.7530 inch)
(2) Idler gear

21
Thickness of idler gear in the air driven The maximum permissible temperature of the
pump ................................ 31.775 to 31.801 mm gear .................................................... 316C (601F)
(1.2510 to 1.2520 inch)
(3) Distance from the end of the idler shaft to the
Pump end clearance gear face ...... 51.0 ± 0.5 mm (2.01 ± 0.02 inch)
Measure the clearance between the back of the The maximum permissible temperature of the
rotor and the machined surface in the bottom gear ................................................. 316 C (601 F)
housing. ................................ 0.013 to 0.076 mm
(0.0005 to 0.0030 inch) (4) Length of gears
(3) Outside diameter of the Drive Shaft ............................ 195.00 ± 0.02 mm
rotor .................................. 85.509 to 85.547 mm (7.677 ± 0.001 inch)
(3.3665 to 3.3680 inch) Idler Shaft ............................. 195.00 ± 0.02 mm
(7.677 ± 0.001 inch)
(4) Idler pocket
(5) Diameter of idler shaft ........ 59.930 ± 0.010 mm
Depth of the idler pocket (air driven (2.3594 ± 0.0004 inch)
pump) ............................... 31.725 to 31.750 mm
(1.2490 to 1.2500 inch)
i01102169
Engine Oil Pump

SMCS Code: 1304
g00288421
Illustration 33
(6) Distance from the top of the dowels to the

surface of the cover ......................... 12 ± 1 mm
(0.47 ± 0.04 inch)
(7) Bore in bearing for idler

shaft .................................... 60.039 ± 0.040 mm
(2.3637 ± 0.0016 inch)
(8) Install the bearings in the cover to the following

depth. ..... 7.50 ± 0.25 mm (0.295 ± 0.010 inch)
(9) Bore in bearing for drive

shaft .................................... 60.039 ± 0.040 mm
(2.3637 ± 0.0016 inch)
(10) Align the oil holes in the bearings with the oil
holes in the cover.
g00288420
Illustration 32
(1) Diameter of new drive

shaft .................................... 59.930 ± 0.010 mm
(2.3594 ± 0.0004 inch)
(2) Distance from the end of the drive shaft to the

gear face .... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)
22
Install the dowel to the following

height. ................... 8 ± 1 mm (0.32 ± 0.04 inch)
(16) Install the dowel in this position for a

counterclockwise rotation of the engine.
(17) Install the dowel in this position for a clockwise

rotation of the engine.
i00642511
Priority Valve
SMCS Code: 5137
g00288422
Illustration 34
(11) Install the bearings in the housing to the

following depth. ...................... 12.30 ± 0.25 mm
(0.484 ± 0.010 inch)
Note: To minimize the press fit, cool the

bearings and the bearing driver to the following
temperature.−75C (−103F)
(12) Bore in bearings in

housing ............................... 60.039 ± 0.040 mm
(2.3637 ± 0.0016 inch)
(13) Align the oil hole in the bearing with the oil Illustration 36
g00287802
hole in the housing.
(1) 1W-2240 Control Valve Spring
(14) The end clearance between the
gears and the housing is the following Length under test force .. 164.0 mm (6.46 inch)
dimension. ................................ 0.14 to 0.26 mm Test force ....................... 435 ± 22 N (98 ± 5 lb)
(0.006 to 0.010 inch) Free length after test ....... 203.8 mm (8.02 inch)
(2) 2G-5664 Spring

Test force ............... 3426 ± 169 N (770 ± 38 lb)
Free length after test ....... 131.3 mm (5.17 inch)
g00288423
Illustration 35
(15) Oil pump cover assembly

23
i01105566 i01105102
Engine Centrifugal Oil Filter Engine Oil Cooler

SMCS Code: 1328 SMCS Code: 1378
g00582338
Illustration 39
(1) During assembly, put a light coat of glycerin

on the O-ring seals. Also, put a light coat of
glycerin in the bores of the elbow.
g00284619 (2) The dimension between the centerline of the first

Illustration 37
bolt hole and the face of the oil cooler bonnets
is the following value. ............... 436.0 ± 1.0 mm
(1) Tighten the studs to the following (17.17 ± 0.04 inch)
torque. ...................... 55 ± 10 N·m (41 ± 7 lb ft)
i01571825
i01571272
Engine Oil Filter Engine Oil Temperature

Regulator
SMCS Code: 1318
SMCS Code: 1330
g00816110
Illustration 38
g00274459
Illustration 40
(1) Put clean engine oil on the O-ring seals at
assembly. When the oil temperature regulator is completely
open, the temperature is the following value. .. 85 C
(185F)
Minimum opening distance at 85 C

(185 F) .................................... 10.4 mm (0.41 inch)
24
i00604967
Crankcase Breather
SMCS Code: 1317
g00283754
Illustration 41
(1) Tighten all crankcase breather clamps to the

following torque. .... 3.0 ± 0.5 N·m (27 ± 4 lb in)
(2) Apply clean engine oil in the bores for the

O-ring seals.
25
i01575647
Water Pump
SMCS Code: 1361
g00287157
Illustration 42
(1) Diameter of the shaft at the seat area of the b. Put clean water on the seal assembly as the
carbon seal assembly ....... 44.450 ± 0.020 mm only lubrication for assembly. DO NOT get
(1.7500 ± 0.0008 inch) any grease or oil on the seal faces.
(2) Seal assembly c. DO NOT stretch the rubber of the seal

assembly at installation. If the seal is
1. Ring and water seal stretched, the service life is shortened.
a. Lubricate the housing bore with a light amount d. Use the 8T-3034 Water Pump Seal Driver
of glycerin. and hand pressure to install the seal assembly
on the pump shaft until the seal face makes
b. Use the 8T-3034 Water Pump Seal Driver light contact with the smooth face of the ring.
and hand pressure in order to install the water
seal (3) and the ring together in the pump Note: The seal assembly must rotate with the water
housing bore. Ensure that the polished face pump shaft. DO NOT use any lubricant (except
of the ring is toward the groove of the seal clean water) that will reduce the friction between
assembly. the seal and the shaft.
2. Seal assembly. e. Install the carbon seal assembly spring.
a. Remove the spring from the seal. (3) Seal. Put a light coat of glycerin on the seal and
in the housing bore at assembly.
26
(4) Diameter of the impeller shaft at the location of The shaft support bearing should be flush with the
the lip type seal .................. 49.200 ± 0.020 mm surface of the pump housing during installation.
(1.9370 ± 0.0008 inch)
(5) Diameter of impeller shaft .. 64.850 ± 0.020 mm

(2.5531 ± 0.0008 inch)
(6) Diameter of the impeller shaft at the support

end. .................................... 88.878 ± 0.013 mm
(3.4991 ± 0.0005 inch)
(7) Put a light coat of glycerin on the O-ring seal

at assembly. Put a light coat of glycerin in the
housing bore at assembly.
(8) Put a light coat of glycerin on the seal at

assembly.
g00287160
Illustration 44
(9) Thickness of thrust washer .... 11.85 ± 0.05 mm Positioning Impeller Shaft Bearing
(0.467 ± 0.002 inch) View A-A
Width of groove in the impeller shaft for the thrust (13) The oil hole in the impeller shaft bearing (10)
washer ........ 12.00 ± 0.05 mm (0.472 ± 0.002 inch) from the horizontal centerline of the pump
housing is the following angle. .. 50 ± 1 degrees
End play for impeller shaft ............. 0.05 to 0.25 mm
(0.002 to 0.010 inch) (14) Install the impeller shaft bearing (10) with
the bearing joint at a 5 degree angle from the
horizontal centerline of the pump housing.
g00287161
Illustration 45
Positioning Shaft Support Bearing
View B-B
g00287158
Illustration 43 (15) The oil hole in the shaft support bearing (12)
from the vertical centerline of the pump housing
(10) Bore in impeller shaft is the following angle. ............... 60 ± 1 degrees
bearing .. 65.00 ± 0.06 mm (2.559 ± 0.002 inch)
(16) Install the shaft support bearing (12) with the
(11) Dimension of impeller shaft bearing from bearing joint at a 15 degree angle from the
surface of pump housing ........... 92.5 ± 1.0 mm vertical centerline of the pump housing.
(3.64 ± 0.04 inch)
(12) Bore in shaft support

bearing .. 89.08 ± 0.06 mm (3.507 ± 0.002 inch)
27
i01130671 i01131209
Water Temperature Regulator Water Temperature Regulator

SMCS Code: 1355 SMCS Code: 1355
Part No.: 6I-4953 Part No.: 6I-4952
S/N: BKE1-Up S/N: BLB1-Up
g00286978 g00286978
Illustration 46 Illustration 48
When the water temperature regulator is completely When the water temperature regulator is completely
open, the temperature is the following value. .. 37 C open, the temperature is the following value. .. 50 C
(99 F) (122 F)
Minimum opening distance at 37 C Minimum opening distance at 50 C

(99 F) ...................................... 10.4 mm (0.41 inch) (122 F) .................................... 10.4 mm (0.41 inch)
i01441957
Water Temperature Regulator

SMCS Code: 1355
Part No.: 174-3504, 6I-4950
g00286978
Illustration 47
When the water temperature regulator is completely

open, the temperature is the following value: .. 92 C
(197 F)
Minimum opening distance at 92 C

(197 F) .................................... 10.4 mm (0.41 inch)
28
i01543000 (3) The dowels protrude from the rear face

of the cylinder block at the following
Cylinder Block distance. ....... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)
SMCS Code: 1201 (3) The dowels protrude from the front face
of the cylinder block at the following
distance. ....... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)
g00480025
Illustration 50
Front View Of Cylinder Block
(5) The dowels protrude above the cylinder block

g00584368
Illustration 49 face at the following distance. ... 60.0 ± 1.0 mm
(2.36 ± 0.04 inch)
(1) Cylinder head studs
Apply 4C-4774 Water and Temperature Resistant
Use the following procedure in order to install the Grease to the dowel before the head is assembled.
cylinder head studs:
(6) The dowels protrude above the cylinder block
1. Coat the lower half of each stud with 1.5 mm face at the following distance. ..... 8.0 ± 1.0 mm
(0.06 inch) thick coating of 4C-4774 Water and (0.32 ± 0.04 inch)
Temperature Resistant Grease.
(7) Procedure for tightening the main bearings
2. Thoroughly clean the top of the cylinder block.
1. Lubricate the stud threads with engine oil before
3. Install the cylinder head studs. assembly.
Tighten the cylinder head studs to the following 2. Torque the studs in the cylinder block.
torque. .................... 100 ± 20 N·m (75 ± 15 lb ft)
Torque for the studs ...................... 100 ± 20 N·m
4. Apply a bead of grease at the top of the block (75 ± 15 lb ft)
around each stud. This will ensure that the
counterbore is filled with grease. 3. Assemble the main bearing cap and the washer
with the part number toward the front of the
5. Coat the upper half of each stud with 1.5 mm engine block. Hand tighten the nut.
(0.06 inch) thick coating of 4C-4774 Water and
Temperature Resistant Grease. 4. Tighten all side bolts (9) by hand. Lubricate
the washer face and the threads with engine oil
(2) Apply 8T-9014 Silicone Sealant to the covers before assembly.
when the covers are installed to the block.
29
5. Start at the front face of the block.
Tighten the side bolts on the side of the

cap with the tab slot to the following
torque. .................. 215 ± 40 N·m (160 ± 30 lb ft)
6. Start at the front face of the block. Use the

4C-5850 Stud Tensioner Tool Group in order to
apply tension on the studs.
Apply tension on each pair of studs

at the same time to the following
pressure. .... 65000 ± 2400 kPa (9400 ± 350 psi)
Tighten the nuts by hand and release the tension.
7. Repeat Step 6.
Tighten the side bolts on the side of the

cap opposite the tab slot to the following Illustration 51 g00584867
torque. .................. 215 ± 40 N·m (160 ± 30 lb ft) Rear view Of Cylinder Block
9. Start at the front face of the block. (10) The dowels protrude above the cylinder block
face at the following distance. ..... 8.0 ± 1.0 mm
Tighten the side bolts on the side of the (0.32 ± 0.04 inch)
cap with the tab slot to the following
torque. .......... 1825 ± 175 N·m (1340 ± 130 lb ft) (11) Width of main bearing cap .. 499.95 ± 0.03 mm
(19.683 ± 0.001 inch)
Width of cylinder block for main bearing
Tighten the side bolts on the side of the cap .......... 500.00 ± 0.05 mm (19.685 ± 0.002 inch)
cap opposite the tab slot to the following
torque. .......... 1825 ± 175 N·m (1340 ± 130 lb ft) Clearance between the sides of the main bearing
cap and the cylinder block ............ 0.03 to 0.13 mm
(8) Bore in the block for main (0.001 to 0.005 inch)
bearings ........................... 265.000 ± 0.020 mm
(10.4330 ± 0.0008 inch)
1.00 mm (0.040 inch)

oversize .................................. 266.000 ± 0.020 mm
(10.4724 ± 0.0008 inch)
2.00 mm (0.080 inch)

oversize .................................. 267.000 ± 0.020 mm
(10.5118 ± 0.0008 inch)
g00584890
Illustration 52
Main Bearing Cap
(12) The dowel protrudes from the main bearing

cap at the following distance. .... 10.0 ± 0.5 mm
(0.39 ± 0.02 inch)
(13) Main bearing cap

30
i01542287 2. Apply 4C-5592 Anti-Seize Compound to the

threads and seating surfaces of bolts (4) and (5).
Crankshaft
3. Seat the counterweight by tightening bolt (4) first.
SMCS Code: 1202
Tighten bolt (4) to the following
torque. ............ 1500 ± 100 N·m (1100 ± 75 lb ft)
Tighten bolts (5) to the following

torque. ............ 1500 ± 100 N·m (1100 ± 75 lb ft)
4. Loosen bolt (4) and bolts (5).
5. Reseat the counterweight by tightening bolt (4)

first.

torque. .................. 320 ± 30 N·m (240 ± 22 lb ft)
g00290564 Tighten bolts (5) to the following

Illustration 53
torque. .................. 320 ± 30 N·m (240 ± 22 lb ft)
(1) Thickness of thrust plates ...... 13.80 ± 0.05 mm
6. Check the torque on bolt (4).
(0.543 ± 0.002 inch)
Install the thrust plates on the rear main bearing for
torque. .................. 320 ± 30 N·m (240 ± 22 lb ft)
rear driven equipment. Install the thrust plates on
the front main bearing for front driven equipment.
7. Tighten bolt (4) first.
(2) Diameter of new connecting rod
Tighten bolt (4) to the following required
journals ............................. 216.000 ± 0.025 mm
amount. ..................................... 120 ± 5 degrees
(8.5039 ± 0.0010 inch)
Tighten bolts (5) to the following required
(3) Diameter of new main bearing
amount. ..................................... 120 ± 5 degrees
journals ............................. 250.000 ± 0.025 mm
(9.8425 ± 0.0010 inch)
g00801223
Illustration 55
g00290565 Detail A
Illustration 54
Section A-A
8. Insert locking pin (6) into Area (A) or Area (B).
Tighten the counterweight bolts according to the
Note: The angle of Area (A) is 120 degrees. The
following procedure.
angle of Area (B) is 120 degrees.
1. Install the counterweight with the heavy side
toward the rod.
31
g00290566 g00310823
Illustration 56 Illustration 58
Detail Of Throw Of Crankshaft (Pin Number 5)
(7) Oil plugs of crankshaft
(11) Dimension A
Tighten the crankshaft plugs (7) to the following
torque. ...................... 300 ± 40 N·m (221 ± 30 lb ft) (12) Zone A
(8) Crankshaft timing pin bracket When the engine is positioned and the engine is
anchored, the following measurements must be
(9) Crankshaft end play ............... 0.175 to 0.60 mm taken between the cheeks of Pin Number 5:
(0.0069 to 0.0236 inch)
• Dimension A (11)
• Zone A (12)
Use the following procedure in order to measure the
change in dimension A (11) within zone B (12).
1. Rotate the counterweight as close as possible

to the top center position. Ensure that the dial
indicator does not interfere with the connecting
rod.
2. Seat the pivot points of the dial indicator by

spinning the dial indicator.
g00290567
Illustration 57 3. Set the dial indicator to zero.
Section B-B
Crankshaft Timing Pin Bracket 4. Rotate the crankshaft from the starting position
until the dial indicator approaches interference
(10) The dowel extends from the crankshaft with the connecting rod on the opposite side.
timing pin bracket at the following Observe the readings of the dial indicator while
distance. ......... 5.0 ± 1.0 mm (0.20 ± 0.04 inch) the crankshaft is rotated.
5. Rotate the crankshaft to the starting position.

The dial indicator must return to zero. If the dial
indicator does not return to zero repeat Steps 1
through 5.
When the engine is at the ambient temperature,

the change in dimension A must not exceed the
following TIR. ....................... 0.04 mm (0.0016 inch)
32
i01542690 (5) Apply clean engine oil to the O-ring seals at

assembly.
Crankshaft Seals
(6) Position the sleeves on the adapters. Make sure
SMCS Code: 1160; 1161 that the arrow on the outside diameter of the
sleeve is pointing in the direction of the rotation
of the crankshaft. Assemble the sleeve onto the
adapter. Make sure that the adapter bottoms out
against the shoulder.
i01543387
Connecting Rod
SMCS Code: 1218
g00304423
Illustration 59
(1) Crankshaft seals must be installed with the lip

of the seal toward the inside of the engine, as
g00287846
shown above. Make sure that the correct seal is Illustration 60
installed on each end of the crankshaft.
(1) Bore in connecting rod for piston pin
An SAE standard rotation engine will have crankshaft bearing ............................. 130.000 ± 0.015 mm
seals that are installed in the following locations: (5.1181 ± 0.0006 inch)
• 190-2462 Seal Assembly on the front of the The piston pin bearing may be installed in the
engine connecting rod by using either of the following
methods:
• 190-2463 Seal Assembly on the rear of the
engine 1. Lower the temperature of the piston pin bearing
before installing the piston pin bearing in the
An SAE opposite rotation engine will have crankshaft connecting rod. This is the preferred method of
seals that are installed in the following locations: installation.
• 190-2463 Seal Assembly on the front of the Minimum temperature to cool piston pin
engine bearing ......................................... −90C (−130F)
• 190-2462 Seal Assembly on the rear of the 2. Raise the temperature of the piston pin end of
engine the connecting rod before installing the bearing.
This must be for a minimum length of 250 mm
(2) Rear face of cylinder block (10 inch). Raise the temperature evenly. Raise
the temperature thoroughly. This is the alternative
(3) Front face of cylinder block method.
(4) Apply 4C-4774 Water and Temperature Note: Do not use a torch to heat the connecting rod.
Resistant Grease to the bore of the adapter.
Also, apply the grease to the holes (66 mm Heat the connecting rod to the following
(2.6 inch) diameter) in the adapter. temperature. ............. 190 ± 15C (374 ± 27F)
33
(2) Bore in piston pin bearing for new piston

pin ..................................... 120.114 ± 0.008 mm
(4.7289 ± 0.0003 inch)
Diameter of new piston pin .... 119.994 ± 0.006 mm

(4.7242 ± 0.0002 inch)
Tight fit between connecting rod and piston pin

bearing ....................................... 0.120 to 0.180 mm
(0.0047 to 0.0071 inch)
Note: Assemble the piston pin retainer so the word

“OUT” is visible.
g00807839
Illustration 62
Connecting Rod Bearing Cap
(6) Procedure for tightening connecting rod bolts
Note: Nuts (A) and (B) are on the same side of the
connecting rod that has raised bosses and bearing
tab slots.
1. Tighten nut (A) to a torque of 340 ± 15 N·m

(250 ± 10 lb ft).
2. Tighten nut (D) to a torque of 340 ± 15 N·m

g00287847
Illustration 61 (250 ± 10 lb ft).
Positioning Piston Pin Bearing
3. Tighten nut (B) to a torque of 340 ± 15 N·m
Note: The bearing junction and the locating hole are (250 ± 10 lb ft).
180 degrees across from each other. The bearing
junction and the locating hole must be assembled 4. Tighten nut (C) to a torque of 340 ± 15 N·m
within area (A). Area (A) is 90 ± 15 degrees from (250 ± 10 lb ft).
the centerline through the connecting rod bores.
5. Without loosening the nut, tighten nut (A) again
(3) Bore in bearing for to a torque of 340 ± 15 N·m (250 ± 10 lb ft).
crankshaft ..................... 216.145 to 216.306 mm
(8.5096 to 8.5160 inch) 6. Without loosening the nut, tighten nut (D) again
to a torque of 340 ± 15 N·m (250 ± 10 lb ft).
(4) Bore in connecting rod for
bearing ............................. 225.000 ± 0.015 mm 7. Without loosening the nut, tighten nut (B) again
(8.8582 ± 0.0006 inch) to a torque of 340 ± 15 N·m (250 ± 10 lb ft).
Clearance between bearing and 8. Without loosening the nut, tighten nut (C) again
crankshaft ................................... 0.171 to 0.282 mm to a torque of 340 ± 15 N·m (250 ± 10 lb ft).
(0.0067 to 0.0111 inch)
9. Loosen nut (A) and then tighten nut (A) to a
(5) Distance between center of torque of 15 ± 3 N·m (133 ± 27 lb in).
bearings .................... 600.00 mm (23.622 inch)
Note: Use a 9U-5017 Torque Wrench or a 9S-7354
Torque Wrench to tighten the nuts to a torque of
15 ± 3 N·m (133 ± 27 lb in).
10. Place an index mark on nut (A). Rotate nut (A)

for 360 ± 5 degrees in a clockwise direction.
11. Loosen nut (D) and then tighten nut (D) to a

torque of 15 ± 3 N·m (133 ± 27 lb in).
12. Place an index mark on nut (D). Rotate nut (D)

34
13. Loosen nut (B) and then tighten nut (B) to a Clearance between bearing and new
torque of 15 ± 3 N·m (133 ± 27 lb in). journal .. 0.265 to 0.385 mm (0.0104 to 0.0152 inch)
14. Place an index mark on nut (B). Rotate nut (B)

i01544249
15. Loosen nut (C) and then tighten nut (C) to a

Piston and Rings
torque of 15 ± 3 N·m (133 ± 27 lb in). SMCS Code: 1214; 1215
16. Place an index mark on nut (C). Rotate nut (3)
i01131230
Connecting Rod and Main

Bearing Journals
SMCS Code: 1230
Refer to Main Bearings And Connecting Rod

Bearings Guidelines For Reusable Parts, SEBF8009
for more information.
g00290542
Illustration 63
Connecting Rod Bearing Journals
Table 1
Diameter Of Crankshaft Journal (Bearing Surface)

For Connecting Rod Bearings
216.000 ± 0.025 mm
Original Size Journal
(8.5039 ± 0.0010 inch)
Undersize Journal 215.500 ± 0.025 mm

0.50 mm (0.020 inch) (8.4843 ± 0.0010 inch)

1.00 mm (0.040 inch) (8.4646 ± 0.0010 inch)
Clearance between bearing and new

journal .. 0.173 to 0.285 mm (0.0068 to 0.0112 inch)
Maximum permissible clearance between bearing

and journal ......................... 0.336 mm (0.0132 inch)
Main Bearing Journals

Table 2
Diameter Of Crankshaft Journal (Bearing

Surface) For Main Bearings
250.000 ± 0.025 mm
Original Size Journal
(9.8425 ± 0.0010 inch)

0.50 mm (.020 inch) (9.8228 ± 0.0010 inch)

1.00 mm (0.040 inch) (9.8031 ± 0.0010 inch)
35
Table 3
Piston And Rings
Item (1) Top Ring (2) Intermediate Ring (3) Oil Control Ring
Width Of Groove In New Piston 5.160 ± 0.010 mm 5.160 ± 0.010 mm 8.050 ± 0.010 mm
(0.2030 ± 0.0004 inch) (0.2030 ± 0.0004 inch) (0.3169 ± 0.0004 inch)
Width Of Piston Ring 4.965 ± 0.025 mm 4.977 ± 0.012 mm 7.976 ± 0.011 mm
(0.1955 ± 0.0010 inch) (0.1959 ± 0.0005 inch) (0.3140 ± 0.0004 inch)
Clearance Between Groove And Piston Ring 0.160 to 0.230 mm 0.161 to 0.205 mm 0.053 to 0.095 mm
(0.0063 to 0.0091 inch) (0.0063 to 0.0081 inch) (0.0021 to 0.0037 inch)
Piston Ring End Gap (1) 1.50 ± 0.20 mm 3.00 ± 0.20 mm 1.10 ± 0.20 mm
(0.059 ± 0.008 inch) (0.118 ± 0.008 inch) (0.043 ± 0.008 inch)
(1) The given value is for rings that are installed in a bore of 300 mm (11.8 inch).
(1) The top ring must be installed with the yellow (1) Groove for the Combustion gasket
colored strip to the right of the ring end gap.
Install the top ring with the “UP-1” facing Depth of groove ....................... 3.50 ± 0.15 mm
upward. (0.138 ± 0.002 inch)
The dimension must not vary more than the
(2) The intermediate ring must be installed with the following value. ............ 0.020 mm (0.0008 inch)
green colored strip to the right of the ring end
gap. Install the intermediate ring with the “UP-2” (2) Bore in new liner .............. 300.025 ± 0.025 mm
facing upward. (11.8120 ± 0.0010 inch)
(3) Install the oil control ring and the ring expander Note: Measure the bore at four locations along
with the gaps at an angle of 180 degrees across the depth of the liner. Each location should be 90
from each other. The white colored portion of degrees from each other.
the ring expander must be visible through the
oil control ring gap. (3) Flange
Thickness of flange ................ 33.00 ± 0.03 mm
Bore in piston for pin .................. 120.20 ± 0.05 mm (1.299 ± 0.001 inch)
(4.732 ± 0.002 inch)
The dimension must not vary more than the
following value. ............ 0.013 mm (0.0005 inch)
Diameter of piston pin ............ 119.994 ± 0.006 mm
(4.7242 ± 0.0002 inch)
Clearance between piston pin and bore in

piston ... 0.150 to 0.262 mm (0.0059 ± 0.0103 inch)
i01544344
Cylinder Liner
SMCS Code: 1216
g00288319
Illustration 64
36
i01130581
Camshaft Bearings
SMCS Code: 1211
g00480148
Illustration 65
Note: The left camshaft bearings and the right

camshaft bearings in the rear of the cylinder block
must be installed so that the engine timing pin
will pass freely through the cylinder block and the
bearing.
(1) Angle from the horizontal centerline to the

center of the timing pin hole in the rear camshaft
bearings .................................... 25 ± 5 degrees
(2) Install the camshaft bearings with the bearing

joint toward the top face of the cylinder block.
(3) Bore in camshaft bearings after

installation ............................. 174.00 ± 0.06 mm
(6.850 ± 0.002 inch)
Diameter of the camshaft

journals ..... 173.80 ± 0.03 mm (6.843 ± 0.001 inch)
37
i01130593
Camshaft Bearing Position

SMCS Code: 1211
S/N: BKE1-Up
g00480206
Illustration 66
Right Side View
The right camshaft bearings from the front surface (F) .................. 459.0 ± 1.5 mm (18.07 ± 0.06 inch)
of the cylinder block are the following dimensions:
(G) ..... The front camshaft bearing should be flush
(A) ............. 2759.0 ± 1.0 mm (108.62 ± 0.04 inch) with the front surface of the cylinder block.
(B) ............... 2299.0 ± 1.5 mm (90.51 ± 0.06 inch)
(C) ............... 1839.0 ± 1.5 mm (72.40 ± 0.06 inch)
(D) ............... 1379.0 ± 1.5 mm (54.29 ± 0.06 inch)
(E) ................. 919.0 ± 1.5 mm (36.18 ± 0.06 inch)

38
g00480207
Illustration 67
Left Side View
The left camshaft bearings from the front surface of

the cylinder block are the following dimensions:
(H) ...... The rear camshaft bearing should be flush

with the rear surface of the cylinder block.
(I) ................. 2381.0 ± 1.5 mm (93.74 ± 0.06 inch)
(J) ................ 1921.0 ± 1.5 mm (75.63 ± 0.06 inch)
(K) ............... 1461.0 ± 1.5 mm (57.52 ± 0.06 inch)
(L) ................ 1001.0 ± 1.5 mm (39.41 ± 0.06 inch)
(M) ................. 541.0 ± 1.5 mm (21.30 ± 0.06 inch)
(N) ..................... 81.0 ± 1.0 mm (3.19 ± 0.04 inch)

39
i01130603
Camshaft Bearing Position

SMCS Code: 1211
S/N: BLB1-Up
g00480325
Illustration 68
Right Side View
The right camshaft bearings from the front surface (I) ....... The front camshaft bearing should be flush
of the cylinder block are the following dimensions: with the front surface of the cylinder block.
(A) ............. 3679.0 ± 1.0 mm (144.84 ± 0.04 inch)
(B) ............. 3219.0 ± 1.5 mm (126.73 ± 0.06 inch)
(C) ............. 2759.0 ± 1.0 mm (108.62 ± 0.04 inch)
(D) ............... 2299.0 ± 1.5 mm (90.51 ± 0.06 inch)
(E) ............... 1839.0 ± 1.5 mm (72.40 ± 0.06 inch)
(F) ................ 1379.0 ± 1.5 mm (54.29 ± 0.06 inch)
(G) ................. 919.0 ± 1.5 mm (36.18 ± 0.06 inch)
(H) ................. 459.0 ± 1.5 mm (18.07 ± 0.06 inch)

40
g00480328
Illustration 69
Left Side View
The left camshaft bearings from the front surface of i01131283

the cylinder block are the following dimensions:
Gear Group (Front)
(J) ....... The rear camshaft bearing should be flush
with the rear surface of the cylinder block. SMCS Code: 1206
(K) ............. 3301.0 ± 1.5 mm (129.96 ± 0.06 inch)
(L) .............. 2841.0 ± 1.5 mm (111.85 ± 0.06 inch)
(M) ............... 2381.0 ± 1.5 mm (93.74 ± 0.06 inch)
(N) ............... 1921.0 ± 1.5 mm (75.63 ± 0.06 inch)
(O) ............... 1461.0 ± 1.5 mm (57.52 ± 0.06 inch)
(P) ............... 1001.0 ± 1.5 mm (39.41 ± 0.06 inch)
(Q) ................. 541.0 ± 1.5 mm (21.30 ± 0.06 inch)

g00288151
Illustration 70
(R) ..................... 81.0 ± 1.0 mm (3.19 ± 0.04 inch)
Bottom View
41
i01131272
Housing (Front)
SMCS Code: 1151; 1162
g00288152
Illustration 71
Front View
(1) Idler shaft
Apply clean engine oil on the O-ring seals at

assembly. For SAE standard rotation engines,
assemble the idler shaft with the oil hole (7) at the
position of 2 o’clock. For SAE opposite rotation
engines, assemble the idler shaft with the oil hole
(7) at the position of 8 o’clock.
For SAE standard rotation engines, assemble the

idler shaft with the oil hole (8) at the position of
5 o’clock. For SAE opposite rotation engines,
assemble the idler shaft with the oil hole (8) at the
position of 11 o’clock .
g00288800
(2) Idler gear Illustration 72
(3) Crankshaft gear (1) The dowels at location (B) extend from
the surface of the housing at the following
Apply 4C-4774 Water and Temperature Resistant distance. ......... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
Grease to the bore of the crankshaft gear prior to
assembly. (2) The dowels at location (A) extend from
the surface of the housing at the following
(4) Install the bearing in the gears to the following distance. ....... 10.0 ± 1.0 mm (0.40 ± 0.04 inch)
depth. ..... 2.50 ± 0.50 mm (0.098 ± 0.020 inch)
(3) The dowels at location (C) extend from
(5) Diameter of idler shafts .......... 69.85 ± 0.02 mm the surface of the housing at the following
(2.750 ± 0.001 inch) distance. ......... 4.0 ± 1.0 mm (0.16 ± 0.04 inch)
Outside diameter of idler gear (4) Magnetic pickup

bearings .. 76.091 ± 0.020 mm (2.996 ± 0.001 inch)
Bore in idler gear for bearings ..... 76.00 ± 0.02 mm

(2.992 ± 0.001 inch)
(6) Thickness of new thrust

washer .. 9.45 ± 0.05 mm (0.372 ± 0.0020 inch)
42
i01131307
Gear Group (Rear)

SMCS Code: 1204; 1206
g00483155
Illustration 73
(1) Camshaft drive gears
(2) Idler gears

Backlash between the camshaft drive gears and
the idler gears ...................... 0.160 to 0.795 mm
(0.0063 to 0.0313 inch) g00483156
Illustration 74
(3) Small cluster idler gear

(7) Mounting bolts for the idler shafts
Backlash between the idler gears and the small
cluster idler gear .................. 0.067 to 0.778 mm Use the following procedure in order to tighten the
(0.0026 to 0.0306 inch) mounting bolts for the idler shaft.
(4) Idler gear
(5) Tighten the bolts that connect the idler gear

to the small cluster idler gear to the following
torque. ................ 135 ± 20 N·m (100 ± 15 lb ft)
(6) Crankshaft gear

Backlash between the idler gear and the
crankshaft ............................. 0.216 to 0.949 mm
(0.0085 to 0.0374 inch)
g00483157
Illustration 75
1. Use the following sequence in order to tighten

and turn the bolts.
Two idler shafts with 8 bolt

patterns ........................................ 1-5-3-7-2-6-4-8
One idler shaft with 10 bolt

pattern ................................. 1-6-3-8-5-10-7-2-9-4
2. Tighten the bolts.

43
Tighten each bolt to the following 8. Loosen the locking guide on the Manual barring
torque. .................. 160 ± 16 N·m (120 ± 12 lb ft) group. Verify the relation of the crankshaft to
the camshaft by installing the timing pins. If
3. Each of the bolts should be turned an additional both timing pins cannot be installed, loosen the
45 ± 5 degrees. bolt and the camshaft drive gear. Repeat the
procedure for installing the camshaft drive gear.
(8) Locking plate and bolts
(10) Outside diameter of idler gear
(9) Bolt that holds the camshaft drive gear in shaft .................................. 149.850 ± 0.020 mm
position (5.8996 ± 0.0008 inch)
Use the following procedure in order to install the (11) Thickness of idler gear thrust
camshaft drive gears: washers .. 9.60 ± 0.05 mm (0.378 ± 0.002 inch)
Note: Use the manual barring group to rotate the (12) Idler gear shaft
engine. The engine should be prelubed before
rotating the crankshaft in order to perform service Outside diameter of the shaft for the small
work. Rotating the crankshaft before prelube may cluster idler gear .............. 105.860 ± 0.020 mm
cause damage to the crankshaft bearings if the (4.1677 ± 0.0008 inch)
mating surface is dry. Height to top of dowel in shaft .... 7.0 ± 0.5 mm
(0.28 ± 0.02 inch)
1. Rotate the engine to the Top Center Position
of the compression stroke for the number one
cylinder. Install the crankshaft timing pin.
NOTICE
If the crankshaft timing pin location is missed, do not
turn the flywheel in the opposite direction to install the
crankshaft timing pin. If the crankshaft timing pin loca-
tion is missed, repeat Step 1.
2. Install the camshaft timing pin.
3. Put the camshaft drive gear (1) in position on the

camshaft. Install the plate and the bolt hand tight. g00483159
Illustration 76
Note: Make sure that the gear taper and the
camshaft taper are clean and dry. Make sure that (13) Install the bearing in small cluster idler gear
the gear taper and the camshaft taper are free of (3) to the following depth. ............ 3.0 ± 0.5 mm
dirt, rust and lubricants. (0.12 ± 0.02 inch)
4. To prevent the crankshaft from turning, engage (14) Bearing for the small cluster idler gear
the Manual barring group. Outside diameter of bearing for small cluster
idler gear (3) .................... 114.171 ± 0.026 mm
Tighten the locking guide to the following (4.4949 ± 0.0010 inch)
torque. .................. 270 ± 25 N·m (200 ± 18 lb ft) Bore in gear for bearing .. 114.000 ± 0.020 mm
(4.4882 ± 0.0008 inch)
5. Use a torque multiplier to tighten the camshaft
bolt.
Apply 4C-5591 Anti-Seize Compound to the

threads and the seating face of the bolt. Tighten
the bolt to the following torque. .. 2000 ± 275 N·m
(1480 ± 200 lb ft)
6. Strike the plate with a hammer in order to seat

the gear taper on the camshaft. Repeat Step 5.
7. Repeat Step 6 until there is no change in the

bolt torque.
44
(2) Tighten bolts (1/2) to the following

torque. ................ 135 ± 20 N·m (100 ± 15 lb ft)

torque. ................ 135 ± 20 N·m (100 ± 15 lb ft)

torque. ................ 270 ± 40 N·m (200 ± 30 lb ft)
g00483240
Illustration 77
(15) Install the bearing in idler gear (2) to the

following depth. ............................ 3.0 ± 0.5 mm
(0.12 ± 0.02 inch)
(16) Bearing for the idler gear

Inside diameter of bearing for idler gear
(2) ..................................... 150.002 ± 0.020 mm
(5.9056 ± 0.0008 inch)
Bore in gear for bearing .. 160.000 ± 0.020 mm
(6.2992 ± 0.0008 inch)
i01131302
Housing (Rear)
SMCS Code: 1157
g00477611
Illustration 78
(1) Tighten the four plugs to the following

torque. .................. 125 ± 15 N·m (90 ± 11 lb ft)
Put clean engine oil on the O-ring seals at assembly.

45
i00915946
Vibration Damper
(Dual)
SMCS Code: 1205
S/N: BKE1-Up
g00467780
Illustration 79
(1) Dash mark (7) Damper to crankshaft adapter
(2) Center of inner damper (8) Crankshaft gear
Align the center mark on the damper with the mark (9) Crankshaft
on the crankshaft.
Position the sleeve on the adapter so that the arrow
(3) Center of outer damper on the sleeve is pointing in the direction of the
crankshaft rotation.
When the damper is installed the mark should be
rotated 36 degrees clockwise as the damper is (10) Lower bolt hole
viewed from the front of the engine.
The lower bolt hole is offset. Align the dash marks
(4) Tighten the bolts to the following for the correct orientation.
torque. ........ 1350 ± 150 N·m (1000 ± 110 lb ft)
(5) Outer vibration damper torque. ........ 1350 ± 150 N·m (1000 ± 110 lb ft)
(6) Inner vibration damper

46
i00651428
Vibration Damper
(Single)
SMCS Code: 1205
S/N: BLB1-Up
g00289513
Illustration 80
(1) Vibration damper
Install the vibration damper with the dash mark and

the number 1 piston at the top center position.

torque. ........ 1350 ± 150 N·m (1000 ± 110 lb ft)
47
i01576944
Flywheel
SMCS Code: 1156
g00287056
Illustration 81
Refer to Testing And Adjusting, “Flywheel Runout”

for the correct method of flywheel inspection.
(1) Dash marks
Note: When the flywheel is installed, put the dash

mark on the flywheel near the pilot bore in alignment
with the dash mark on the crankshaft.

torque. .......... 1150 ± 150 N·m (840 ± 110 lb ft)
(3) Put 4C-5593 Anti-Seize Compound on the

washer face and the bolt threads. Tighten the
bolts to the following torque. ....... 800 ± 80 N·m
(590 ± 60 lb ft)
Tighten the bolts to an additional 90 ± 5 degrees.
(4) Install the ring gear on the flywheel with the

chamfer in the ring gear toward the engine.
48
i01131331 (6) Tighten the bolts to the following

torque. ................ 620 ± 80 N·m (460 ± 60 lb ft)
Flexible Coupling
SMCS Code: 3279 i00921776
Flexible Drive
SMCS Code: 3279
g00471112
Illustration 83

g00529056
Illustration 82 torque. .............. 825 ± 100 N·m (608 ± 74 lb ft)
Typical Example
(2) Spacer assembly
torque. ........ 1450 ± 150 N·m (1060 ± 110 lb ft) Note: The bolts, nuts and washers that assemble
the two halves of the spacer assembly (2) must
(2) Spacer assembly be removed after the flexible coupling has been
installed and prior to engine operation.
Note: The bolts, nuts and washers that assemble
the two halves of the spacer assembly (2) must
be removed after the flexible coupling has been
installed and prior to engine operation.

torque. ................ 695 ± 35 N·m (510 ± 26 lb ft)

torque. ................ 710 ± 40 N·m (520 ± 30 lb ft)

torque. ................ 265 ± 15 N·m (195 ± 10 lb ft)
49
i00916712 i00609989
Manual Barring Group Engine Support

(Air Interlock) SMCS Code: 7060
SMCS Code: 1235
g00284635
Illustration 86
g00283576
Illustration 84
torque. ............ 1125 ± 100 N·m (820 ± 75 lb ft)
(1) Tighten the nut to the following
torque. ................ 270 ± 25 N·m (200 ± 18 lb ft) (2) The projection of the dowel beyond the
surface of the support is the following
Note: For information on the manual barring group,
length. ................. 20 ± 1 mm (0.79 ± 0.04 inch)
refer to Testing And Adjusting.
i01544521
i00916886
Engine Lifting Bracket Belt Tension Chart

SMCS Code: 1357
SMCS Code: 1122
Note: Do not use the belt tension charts for belts
with tensioners that are spring loaded.
g00468227
Illustration 85
Position the bracket on the engine so that the hole

in the clevis is in a horizontal plane.
(1) Tighten the nuts to the following

torque. ........ 2150 ± 250 N·m (1580 ± 185 lb ft)
Apply 5P-3931 Anti-Seize Compound to nuts prior

to assembly.
50
Table 4
Belt Tension Chart
Kent-Moore Gauge
Gauge Reading
Numbers
Size of
Width of Belt Number
Belt Belt Tension Belt Tension Number of the
of the Old
“Initial”(1) “Used”(2)(3) New Gauge
Gauge
534 ± 111 N
3/8 10.72 mm (0.422 inch) 400 ± 22 N (90 ± 5 lb) BT-33-97 BT 3397
(120 ± 25 lb)
578 ± 111 N
1/2 13.89 mm (0.547 Inch) 445 ± 44 N (100 ± 10 lb) BT-33-97 BT 3397
(130 ± 25 lb)
712 ± 111 N BT-33-
5V 15.88 mm (0.626 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N BT-33-
11/16 17.48 mm (0.688 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N BT-33-
3/4 19.05 mm (0.750 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N
15/16 23.83 mm (0.938 Inch) 445 ± 44 N (100 ± 10 lb) BT-33-77 BT 3372C
(160 ± 25 lb)
1068 ± 111 N
8PK 27.82 mm (1.095 inch) 890 ± 44 N (200 ± 10 lb) BT-33-109 BT 33109
(240 ± 25 lb)
801 ± 111 N
6PK 20.94 mm (0.824 Inch) 667 ± 44 N (150 ± 10 lb) BT-33-109 BT 33109
(180 ± 25 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
51
Table 5
For DAYCO Supplied Belts Only
Belt Tension Belt Tension
Size of Belt
“Initial”(1) “Used”(2)(4)
.380 (V-Belt) 623 ± 22 N (140 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.440 (V-Belt) 667 ± 22 N (150 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.500 (V-Belt) 712 ± 22 N (160 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.600 (V-Belt) 779 ± 22 N (175 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.660 (V-Belt) 890 ± 22 N (200 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.790 (V-Belt) 890 ± 22 N (200 ± 5 lb) 245 - 534 N (100 ± 5 lb)
4 - RIB PVK 623 ± 22 N (140 ± 5 lb) 267 - 445 N (90 ± 5 lb)
5 - RIB PVK 779 ± 22 N (175 ± 5 lb) 334 - 556 N (100 ± 5 lb)
6 - RIB PVK 934 ± 22 N (210 ± 5 lb) 400 - 667 N (130 ± 5 lb)
8 - RIB PVK 1157 ± 22 N (260 ± 5 lb) 534 - 890 N (180 ± 5 lb)
10 - RIB PVK 1557 ± 22 N (350 ± 5 lb) 557 - 1112 N (230 ± 5 lb)
12 - RIB PVK 1869 ± 22 N (420 ± 5 lb) 800 - 1335 N (270 ± 5 lb)
15 - RIB PVK 2336 ± 22 N (525 ± 5 lb) 1000 - 1669 N (350 ± 5 lb)
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to the “Initial” belt tension.
i01124537 2. Position the sleeve so that the arrow on the outer

diameter of the sleeve is pointing in the direction
Accessory Drive of engine rotation.
SMCS Code: 1207 3. Assemble the sleeve onto the adapter until the
sleeve contacts the shoulder.

torque. ................ 430 ± 60 N·m (320 ± 44 lb ft)

torque. ................ 430 ± 60 N·m (320 ± 44 lb ft)
g00594729
Illustration 87
Use the following procedure in order to install the

sleeve (1).
1. Apply 4C-9507 Retaining Compound to the

inner diameter of the sleeve.
52
i01448396 (2) Positive terminal nut

Alternator and Regulator Tighten the positive terminal nut to the following
torque: ................... 6.2 ± 0.6 N·m (55 ± 5 lb in)
SMCS Code: 1405
(3) Ground terminal nut
Tighten the ground terminal nut to the following
torque: ............... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Regulator
Voltage setting ............................. No adjustment
Permissible voltage range ................ 27 to 29 V
i01448387
Alternator and Regulator

SMCS Code: 1405
g00278489
Illustration 88
g00115456
Illustration 90
g00278491
Illustration 89
Voltage ............................................................... 24 V
Amperage .................................................... 35 Amp
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
Polarity ........................................... Negative ground
Rotation ............................................. Either direction
The minimum full load current at 5000 rpm is the

g00115457
following value: ............................................ 35 Amp Illustration 91
The minimum full load current at 1500 rpm is the Voltage ............................................................... 24 V
following value: ............................................ 11 Amp
Amperage .................................................. 100 Amp
Output voltage ............................................ 28 ± 1 V
Note: Load the battery with a carbon pile 4C-4911
(1) Shaft nut Battery Load Tester in order to get the maximum
alternator output.
Tighten the shaft nut to the following
torque: .................... 110 ± 10 N·m (80 ± 7 lb ft) Polarity ........................................... Negative ground
53
Rotation ............................................. Either direction i01578541
The minimum full load current at 5000 rpm is the Air Starting Motor Pressure
following value: ............................................ 94 Amp Regulating Valve
The minimum full load current at 2000 rpm is the SMCS Code: 1462
following value: .............................................. 9 Amp
Output voltage ......................................... 28 ± 1.0 V
(1) Bolt
Tighten the bolt to the following
torque: ................... 6.2 ± 0.6 N·m (55 ± 5 lb in)
(2) Shaft nut

Tighten the shaft nut to the following
torque: ...................... 102 ± 7 N·m (75 ± 5 lb ft)
(3) Positive terminal nut

g00287035
Tighten the positive terminal to the following Illustration 93
torque: ................... 7.1 ± 0.8 N·m (63 ± 7 lb in)
(1) Adjusting screw
(4) Regulator
(2) Inlet port
Voltage setting ............................. No adjustment
Permissible voltage range ................ 27 to 29 V Inlet pressure ....................... 1724 kPa (250 psi)
Maximum permissible pressure .......... 2758 kPa
(400 psi)
i01599454
(3) Outlet port
Air Starting Motor
Minimum outlet pressure ....... 827 kPa (120 psi)
SMCS Code: 1451 Maximum outlet pressure ...... 965 kPa (140 psi)
i00922474
Pressure Switch
SMCS Code: 7400
g00828891
Illustration 92
(1) Inlet port

Recommended inlet pressure .. 620 kPa (90 psi)
g00471391
Illustration 94
Actuation pressure ......... 462 ± 41 kPa (67 ± 6 psi)
Deactuation pressure ..... 462 ± 41 kPa (67 ± 6 psi)

54
Contact position (B) and i01607724

(C) ..... Normally closed below deactuation pressure
Prelube Pressure Switch
Contact position (A) and
(B) ....... Normally open below deactuation pressure SMCS Code: 7400
(1) Tighten the pressure switch to the following

torque. ........................ 22 ± 3 N·m (16 ± 2 lb ft)
i01269840
Pressure Switch (Hydrax)

SMCS Code: 7400
g00820629
Illustration 96
Actuation pressure ........... 9 ± 3 kPa (1.3 ± 0.4 psi)
Deactuation pressure (minimum) ............. 9 ± 3 kPa

(1.3 ± 0.4 psi)
Contact position ................................ Normally open

below the deactuation pressure
g00289499
Illustration 95
(1) Tighten the switch to the following
torque. ........................ 22 ± 3 N·m (16 ± 2 lb ft)
Actuation pressure .................... 1206 kPa (175 psi)
(2) Receptacle with pin A, pin B, and pin C
Deactuation pressure ....................... 700 ± 103 kPa
(100 ± 15 psi)
i01582114
Contact position (A) and
(C) ..... Normally closed below deactuation pressure Pressure Sensor
Contact position (A) and SMCS Code: 7400-NS; 7450-NS
(B) ....... Normally open below deactuation pressure Part No.: 207-6859
(1) Tighten the pressure switch to the following
torque. ........................ 82 ± 8 N·m (60 ± 6 lb ft)
g00821004
Illustration 97
(1) Pressure sensor

Maximum input pressure ..... ± 2 kPa (± 0.3 psi)
55
Torque ...................... 10 ± 2 N·m (89 ± 18 lb in) i01608375
Temperature Sensor
i01607863
SMCS Code: 7400
Pressure Sensor
SMCS Code: 7400-NS; 7450-NS
Part No.: 163-8523
g00294228
Illustration 100
(1) Sensor assembly
Illustration 98
g00289576 Tighten the sensor assembly to the following
torque. .............................. 20 ± 3 N·m (15 ± 2 lb ft)
(1) Pressure sensor
i01582167
Maximum pressure .............. 1135 kPa (165 psi)
Torque ...................... 10 ± 2 N·m (89 ± 18 lb in) Detonation Sensor
i00651918
SMCS Code: 7400
Pressure Sensor
SMCS Code: 7400-NS; 7450-NS
Part No.: 149-5150
g00821042
Illustration 101
(1) Tighten the sensor to the following

torque. ........................ 15 ± 3 N·m (11 ± 2 lb ft)
g00289515
Illustration 99
(1) Tighten the pressure sensor to the following

torque. .......................... 10 ± 2 N·m (7 ± 2 lb ft)
56
i01599303
Engine Speed/Timing Sensor

SMCS Code: 1905; 1907
g00828745
Illustration 102
(1) Sensor
(2) Bracket
Orient the bracket in proper relation to the sensor.
(3) Bolt
Torque the bolt. ................ 25 ± 6 N·m (18 ± 4 lb ft)

57
Index Section
Index
A Fuel Lines ................................................................ 9
Accessory Drive ................................................... 51

Aftercooler ............................................................ 20 G
Air Cleaner Adapter ............................................... 20
Air Lines (Choke)..................................................... 5 Gas Engine Ignition ................................................ 6
Air Starting Motor ................................................. 53 Gear Group (Front)................................................ 40
Air Starting Motor Pressure Regulating Valve ...... 53 Gear Group (Rear) ................................................ 42
H
B
Housing (Front)...................................................... 41
Belt Tension Chart ................................................ 49 Housing (Rear) ...................................................... 44
C I
Camshaft ................................................................ 9 Important Safety Information ................................... 2

Camshaft Bearing Position ............................. 37, 39
Camshaft Bearings ............................................... 36
Connecting Rod .................................................... 32 M
Connecting Rod and Main Bearing Journals......... 34
Crankcase Breather .............................................. 24 Manual Barring Group (Air Interlock)..................... 49
Crankshaft ............................................................ 30
Crankshaft Seals .................................................. 32
Cylinder Block ....................................................... 28 P
Cylinder Head, Valves, Valve Springs and Valve Seat
Inserts.................................................................. 13 Piston and Rings .................................................. 34
Cylinder Liner ....................................................... 35 Prelube Pressure Switch ....................................... 54
Prelube Pump........................................................ 20
Pressure Sensor.............................................. 54–55
D Pressure Switch..................................................... 53
Pressure Switch (Hydrax)...................................... 54
Detonation Sensor................................................. 55 Priority Valve ......................................................... 22
E S
Electrohydraulic Actuator......................................... 7 Specifications Section ............................................. 4

Electronic Control (Combustion Sensor) ................. 7
Engine Centrifugal Oil Filter .................................. 23
Engine Design ........................................................ 4 T
Engine Lifting Bracket............................................ 49
Engine Oil Cooler ................................................. 23 Table of Contents..................................................... 3
Engine Oil Filter .................................................... 23 Temperature Sensor .............................................. 55
Engine Oil Pump ................................................... 21 Turbocharger ........................................................ 16
Engine Oil Temperature Regulator ........................ 23
Engine Speed/Timing Sensor................................ 56
Engine Support ..................................................... 49 V
Exhaust Bypass Valve .......................................... 18
Exhaust Manifold .................................................. 17 Valve Mechanism ................................................. 11
Vibration Damper (Dual)........................................ 45
Vibration Damper (Single) ..................................... 46
F
Flexible Coupling ................................................... 48 W

Flexible Drive ......................................................... 48
Flywheel ............................................................... 47 Water Pump .......................................................... 25
Fuel Control ............................................................. 8 Water Temperature Regulator .............................. 27
58
Index Section
59
Index Section
©2001 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR5907

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-

Table of Contents Pressure Switch ....................................................

Specifications Section When the crankshaft is viewed from the flywheel

Number and arrangement of cylinders ......... Vee 12

Valves per cylinder

Stroke ........................................ 300 mm (11.8 inch) Exhaust valves ................................................. 2

Thickness of thrust washer ........ 6.00 ± 0.08 mm

Tighten the bolts for the thrust washer to the

Tighten the bolts for the cover assembly to the

2. Hold the plate in the fully closed position and

Tighten the mounting bolts. ............... 12 ± 3 N·m

3. Hold the plate in the closed position. Tighten

Tighten the locking nut to the following

Note: Do not allow the adjusting bolt to turn while

(1) Adjusting bolt

(2) Cover assembly

(3) Thrust washer

Tighten connecting rod end nuts (11) to the

Gas Engine Ignition

1. Install actuator (12) so inlet port (13) and outlet

Tighten rod end nuts (9) for the actuator to the

Electrohydraulic Actuator Electronic Control

(1) Piston assembly

1. Insert the piston assembly into the housing.

Torque .................... 125 ± 15 N·m (92 ± 11 lb ft) g00807399

(3) Plug (1) Extension

Torque ............................... 27 ± 5 N·m (20 ± 4 lb ft) (2) Combustion sensor

(4) Bolts Tighten the combustion sensor to the following

i01549434 Assemble connecting rod (7) so that there is equal

When the fuel valve is in the closed position the

When the fuel valve is in the open position the

Install bearings (4) so the lube fitting is accessible.

Install actuator (1) so the inlet port and the outlet

Assemble connecting rod (12) so that there is equal

When the fuel valve is in the open position the lever

A final adjustment of the linkage is required to g00480001

(1) Thickness of new thrust plate .. 15.00 ± 0.25 mm

(2) Diameter of camshaft

Bore in camshaft bearing after

(2) Tube assembly (4) Timing bolt location

(3) Fuel control valve

(8) Camshaft bearing journal

g00482542 Install the camshaft bearing journals with the

(12) Specified camshaft lobe lift

To find the specified camshaft lobe lift, use the

1. Measure the total height of the camshaft (13).

2. Measure base circle (14).

3. Subtract base circle (14) from the total height of g00284769

(3) Valve lash

(4) Tighten the bridge adjustment screw locknut to

(5) Diameter of bridge dowel .. 19.055 ± 0.003 mm

Diameter of bore in bridge ....... 19.162 ± 0.030 mm

Diameter of bore in plug for

Diameter of plug ....................... 27.050 ± 0.008 mm

Diameter of bore in cylinder head for

(6) Support assembly and the gas admission valve

(7) The guide springs must not be used again.

(12) Tighten the bolts to the following

(8) Guides for the lifters