2 Engine Specifications

RENR8913
September 2006
Specifications
1104D Industrial Engine
NH (Engine)
NJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

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

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
RENR8913 3
Table of Contents
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 5
Fuel Injectors ....................................................... 6
Fuel Transfer Pump ............................................. 6
Fuel Filter Base .................................................... 7
Fuel Priming Pump .............................................. 7
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 8
Valve Mechanism Cover ...................................... 9
Cylinder Head Valves ........................................... 10
Cylinder Head ...................................................... 11
Turbocharger ....................................................... 12
Exhaust Manifold ................................................. 12
Camshaft ............................................................. 13
Camshaft Bearings .............................................. 13
Engine Oil Filter Base .......................................... 14
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 15
Engine Oil Pressure ............................................. 17
Engine Oil Pan ..................................................... 17
Engine Oil Bypass Valve ...................................... 19
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 21
Water Pump ......................................................... 21
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 23
Crankshaft Seals ................................................. 25
Crankshaft Pulley ................................................. 26
Connecting Rod Bearing Journal ......................... 27
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 29
Piston Cooling Jet ................................................. 30
Front Housing and Covers ................................... 30
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 33
Flywheel Housing ................................................ 33
Belt Tension Chart ............................................... 34
Engine Lifting Bracket ........................................... 34
Alternator ............................................................. 34
Starter Motor ........................................................ 36
Coolant Temperature Sensor ............................... 37
Fuel Pressure Sensor .......................................... 37
Engine Oil Pressure Sensor ................................. 37
Boost Pressure Sensor ......................................... 38
Inlet Manifold Temperature Sensor ....................... 38
Crankshaft Position Sensor .................................. 39
Electronic Control Module ..................................... 39
Glow Plugs ........................................................... 40
Index Section
Index ..................................................................... 41
4 RENR8913
Specifications Section When the crankshaft is viewed from the front of

the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise
i02503001
When the camshaft is viewed from the front of
Engine Design the engine, the camshaft rotates in the following
direction: ................................................... Clockwise
The front 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.
i02519279
Fuel Injection Lines
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
g01187485
Refer to Operation and Maintenance Manual,
Illustration 1 “General Hazard Information and High Pressure Fuel
Cylinder and valve location Lines” before adjustments and repairs are performed.
(A) Exhaust valve
(B) Inlet valve Note: Refer to Systems Operation, Testing
and Adjusting, “Cleanliness of Fuel System
Bore ......................................... 105 mm (4.133 inch) Components” for detailed information on the
standards of cleanliness that must be observed
Stroke ...................................... 127 mm (5.000 inch) during ALL work on the fuel system.
Displacement ...................................... 4.4 L (269 in3) Ensure that all adjustments and repairs are performed
by authorized personnel that have had the correct
Cylinder arrangement ..................................... In-line training.
Type of combustion ............................ Direct injection
Compression ratio
Turbocharged engines and turbocharged
aftercooled engines ................................. 16.2:1
Number of cylinders ................................................ 4
Valves per cylinder .................................................. 4
Valve lash
Inlet valve ....................... 0.35 mm (0.0138 inch)
Exhaust valve ................. 0.35 mm (0.0138 inch)
Firing order ................................................. 1, 3, 4, 2

RENR8913 5
Manifold to Injector i02519422
Fuel Injection Pump
Note: Before the pump is removed from the engine

the fuel injection pump shaft must be locked. Position
the engine to TC compression stroke of number one
cylinder before tightening the locking screw. The
locking screw will prevent the shaft from rotating.
If the fuel injection pump was removed prior to
correctly timing the engine and locking the shaft, the
fuel injection pump will need to be timed by trained
personnel. In order to time the fuel injection pump,
refer to Disassembly and Assembly, “Fuel Injection
Pump - Install”.
Note: Refer to Systems Operation, Testing

Components” for detailed information on the
g01260742 standards of cleanliness that must be observed
Illustration 2
Typical example during ALL work on the fuel system.
(1) Tighten the union nuts for the high pressure fuel
lines (1) to the following torque. ............... 30 N·m
(22 lb ft)
Pump to Manifold
g01260784
Illustration 4
Typical example
(1) Locking screw
(2) Washer
g01260743
Illustration 3 (3) Setscrews
Typical example
(4) Support bracket
(1) Tighten the union nuts for the high pressure fuel
line (2) to the following torque. .. 30 N·m (22 lb ft) (5) Setscrew
Locking the shaft

6 RENR8913
Loosen locking screw (1) and move the washer (1) Tighten the nuts to the following torque 2.4 N·m
(2) to the locked position. Tighten the locking (21 lb in).
screw to the following torque. .... 9 N·m (79 lb in)
(2) Tighten the bolt in the clamp for the fuel injection
Unlocking the shaft nozzle to the following torque. .. 27 N·m (19 lb ft)
Loosen locking screw (1) and move the washer (3) Clamp
(2) to the unlocked position. Tighten the locking
screw to the following torque. ..... 9 N·m (79 lb in) (4) O ring seal
(3) Tighten the mounting setscrews to the following (5) Trim code
torque. ...................................... 22 N·m (16 lb ft)
Note: Refer to the Troubleshooting, “Injector Trim
(5) Tighten the mounting setscrew to the following File” for more information.
torque. ...................................... 44 N·m (32 lb ft)
Note: The support bracket must be installed after i02519286

the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the Fuel Transfer Pump
setscrew (5) and then tighten the setscrews (3).
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
i02519280 and Adjusting, “Cleanliness of Fuel System
Fuel Injectors standards of cleanliness that must be observed
during ALL work on the fuel system.

g01260765
Illustration 6
(1) Fuel outlet
(2) Fuel return from cylinder head
(3) Fuel supply
(4) Retaining setscrew
(4) Retaining setscrew ................... 30 N·m (22 lb ft)
The outlet pressure for the fuel ......... 400 to 500 kPa
g01179017 (58.0160 to 72.5200 psi)
Illustration 5
RENR8913 7
i02519336 Hand Fuel Priming Pump

Fuel Filter Base

g01265616
Illustration 8
Typical example
(1) The plunger that is hand operated.
Electric fuel Priming Pump

The electric fuel priming pump operates on 12 volts
or 24 volts.
g01260768 i02392326
Illustration 7
Typical example
Lifter Group
(1) Retaining setscrews ................. 44 N·m (32 lb ft)
(2) The canister for the fuel filter
i02519432
Fuel Priming Pump

g00629433
Illustration 9
(1) Diameter of the lifter body .. 18.987 to 19.012 mm

(0.7475 to 0.7485 inch)
Bore diameter in the cylinder block

............. 19.05 to 19.082 mm (0.7500 to 0.7513 inch)
8 RENR8913
Clearance The service limit for both rocker arm

bores ............................... 0.17 mm (0.0067 inch)
Clearance of the lifter .......... 0.038 to 0.095 mm
(0.0015 to 0.0037 inch) (5) Rocker shaft
Diameter of the rocker
i02504776
shaft .................................. 24.962 to 24.987 mm
Rocker Shaft (0.9828 to 0.9837 inch)
(6) Spring
(7) Snap ring
(8) Spring
(9) Adjuster
(10) Locknut
Torque for the locknut ............... 27 N·m (20 lb ft)
g01253910
Illustration 10
g01254105
Typical example Illustration 11
Tightening sequence
(1) Pedestal
Tighten the fasteners in the sequence that is in
(2) Locator illustration 11. Tighten the fasteners to the following
torque. ............................................. 35 N·m (25 lb ft)
(3) Inlet rocker arm
Diameter of the rocker arm bore
.... 25.031 to 25.051 mm (0.9855 to 0.9863 inch)
(4) Exhaust rocker arm

Diameter of the rocker arm
bore .................................. 25.031 to 25.051 mm
(0.9855 to 0.9863 inch)
Clearance
Maximum clearance of both the rocker arm
bores ............................. 0.089 mm (0.0035 inch)
RENR8913 9
i02503083
Valve Mechanism Cover
g01252367
Illustration 12
Typical example
Tighten the bolts for the valve mechanism cover in

the sequence that is shown in illustration 12 to the
following torque. ................................ 6 N·m (53 lb in)
10 RENR8913
i02503124
Cylinder Head Valves
g01193821
Illustration 14
(2) Valve face angle

Inlet ................................................... 30 degrees
Exhaust ............................................. 45 degrees
(3) Valve stem diameter

Inlet .. 5.942 to 5.957 mm (0.2339 to 0.2345 inch)
Exhaust ................................. 5.927 to 5.942 mm
(0.2333 to 0.2339 inch)
Clearance
Maximum clearance of the inlet valve
stem ................................ 0.05 mm (0.0020 inch)
g01164859
The service limit for the inlet valve
Illustration 13 stem ................................ 0.08 mm (0.0031 inch)
Typical example
Clearance
The valve spring (1) may be used on the inlet valve
or the exhaust valve. When the valve springs are Maximum clearance of the exhaust valve
replaced the valve springs must be replaced in pairs. stem .............................. 0.065 mm (0.0026 inch)
The service limit for the inlet valve
Table 1 stem ................................ 0.09 mm (0.0035 inch)
The load for the valve The length of the valve
spring spring (4) Length of valve
161.5 to 178.5 N 31.5 mm (1.2402 inch) Inlet valve ..................... 107.925 to 108.375 mm
(36.3 to 40.1 lb) (4.2490 to 4.2667 inch)
Exhaust valve ............... 107.703 to 108.153 mm
337.9 ± 373.5 N (76 ± 84 lb) 21.5 mm (0.8465 inch) (4.2403 to 4.2580 inch)
(5) Valve head

Diameter of inlet valve head .................... 35 mm
(1.3780 inch)
Diameter of exhaust valve head .............. 33 mm
(1.2992 inch)
RENR8913 11
i02505671 Note: The maximum distortion of the bottom face of

the cylinder head is given in table 2.
Cylinder Head
Table 2
Maximum Permissible
Dimension
Distortion
Width (A) 0.03 mm (0.0018 inch)
Length (B) 0.05 mm (0.0019 inch)
Diagonal Line (C) 0.05 mm (0.0019 inch)
g01250785
Illustration 15
Typical example
Lubricate the threads and the underside of the head

bolts with clean engine oil.
Tighten the bolts in the sequence that is shown in
illustration 15 to the following torque. ...... 50 N·m
(37 lb ft)
Tighten the bolts again to the following
torque. .................................... 100 N·m (74 lb ft)
Tighten the head bolts to the additional
amount. ........................................... 225 degrees
Minimum thickness of cylinder head ....... 100.95 mm

(3.9744 inch)
g01185843
Illustration 17
Typical example
(1) Valve guide bores

Inlet and exhaust .................. 5.979 to 5.992 mm
(0.2354 to 0.2359 inch)
(2) Valve depths

Inlet .. 0.905 to 1.163 mm (0.0356 to 0.0458 inch)
The service limit for the depth of the inlet valve
........................................ 1.41 mm (0.0555 inch)
Exhaust ................................. 0.876 to 1.131 mm
(0.0345 to 0.0445 inch)
The service limit for the exhaust valve
depth ............................... 1.38 mm (0.0543 inch)
g01254471
Illustration 16
Typical example
12 RENR8913
i02527109 Table 3
Turbocharger The part number for

the turbocharger
The pressure for the
wastegate
2674A804 112 kPa (16.2445 psi)
2674A805 112 kPa (16.2445 psi)
2674A806 112 kPa (16.2445 psi)
2674A607 112 kPa (16.2445 psi)
2674A608 112 kPa (16.2445 psi)
2674A609 100 kPa (14.5040 psi)
2674A611 100 kPa (14.5040 psi)
2674A612 100 kPa (14.5040 psi)
i02504751
Exhaust Manifold
g01265255
Illustration 18
Typical example
(1) Turbocharger
g01253896
Illustration 19
(2) Actuator Typical example
(3) Actuator rod Tighten the exhaust manifold bolts in the sequence
that is shown in illustration 19 to the following
The maximum test pressure for the torque. ............................................. 40 N·m (30 lb ft)
wastegate .............................. 112 kPa (16.2445 psi)
The movement for the rod actuator ................. 1 mm

(0.0394 inch)
RENR8913 13
i02526614 Table 4
Camshaft Camshaft Journals Standard Diameter

50.711 to 50.737 mm
1
(1.9965 to 1.9975 inch)
50.457 to 50.483 mm
2
(1.9865 to 1.9875 inch)
49.949 to 49.975 mm
3
(1.9665 to 1.9675 inch)
Maximum wear on the camshaft journals ... 0.05 mm

(0.0021 inch)
Check the camshaft lobes for visible damage. If a

new camshaft is installed you must install new lifters.
i02505262
Camshaft Bearings
g00987750
Illustration 20
Checking the end play of the camshaft
(1) End play of a camshaft ......... 0.126 to 0.558 mm

(0.0050 to 0.0220 inch)
Maximum permissible end play of a worn

camshaft ............................... 0.62 mm (0.0244 inch)
g01195129
Illustration 21
Typical example
(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m
(70 lb ft)
g01254209
(3) The diameters of the camshaft journals are given Illustration 22
in the following tables. Typical example
(1) The diameter of the installed camshaft

bearing .............................. 50.787 to 50.848 mm
(1.9995 to 2.0019 inch)
14 RENR8913
i02505073
Engine Oil Filter Base
g01254115
Illustration 24
Typical example
(3) Setscrew
Tighten the setscrews to the following
g01254114 torque. .......................................... 22 N·m (16 ft)
Illustration 23
Typical example (4) Engine oil filter
(1) Setscrew Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)
Tighten the setscrews to the following
torque. .......................................... 22 N·m (16 ft) (5) Plug
(2) Engine oil filter Tighten the plug to the following torque. .. 12 N·m
(8 lb ft)
Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)
RENR8913 15
i02505212 i02505677
Engine Oil Cooler Engine Oil Pump
Engines with Balancer Group

Type ............................. Gear-driven differential rotor
Number of lobes
Inner rotor ......................................................... 6
Outer rotor ........................................................ 7
g00952614
Illustration 25
Typical example
(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
(6) Setscrew
(7) Setscrew
g00989248
Illustration 27
The oil pump for the balancer
(1) Clearance of the outer rotor to the

body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)
g01254185
Illustration 26
Setscrews
Tighten the setscrews (7) to the following
torque. ...................................... 22 N·m (16 lb ft)
Setscrews
Tighten the setscrews (4) and (6) in the sequence
that is in illustration 26 to the following torque.
.................................................. 22 N·m (16 lb ft)
16 RENR8913
g00938724
Illustration 30
The end cover
(4) Torque for cover bolts for oil pump .......... 26 N·m
(19 lb ft)
g00989236
Illustration 28
Inner rotor
(2) Clearance of inner rotor to outer

rotor ...................................... 0.050 to 0.200 mm
(0.0020 to 0.0079 inch)
g00989519
Illustration 31
Idler gear and pump gear
Note: Replace the idler gear bolt (5) and the nut for
the oil pump gear (6).
(5) Tighten the idler gear bolt to the following

torque. ...................................... 26 N·m (19 lb ft)
Note: Set the engine to the TC position. Refer to

Systems Operation, Testing and Adjusting Manual,
“Finding Top Center Position for No. 1 Piston”. Install
the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”. Install the gear for the oil pump
g00989217
Illustration 29 and tighten the nut (6).
The end play for the rotor
(6) Tighten the nut to the following torque. .... 95 N·m
(3) End play of rotor assembly (70 lb ft)
Inner rotor .................................. 0.04 to 0.11 mm Tighten the bolts that hold the balancer to the cylinder
(0.0016 to 0.0043 inch) block to the following torque. .......... 54 N·m (40 lb ft)
Outer rotor ................................ 0.04 to 0.00 mm
(0.0016 to 0.0043 inch)
Engines without Balancer Group
Type ............................. Gear-driven differential rotor
RENR8913 17
Number of lobes (3) End play of rotor assembly

Inner rotor ......................................................... 5 Inner rotor ............................. 0.038 to 0.089 mm
Outer rotor ........................................................ 6 (0.0014 to 0.0035 inch)
Outer rotor ............................ 0.025 to 0.076 mm
(0.0010 to 0.0029 inch)
Tighten the bolts that hold the front cover of the oil
pump assembly to the following torque. ........ 26 N·m
(19 lb ft)
i01958104
Engine Oil Pressure
g00938064
Illustration 32
The minimum oil pressure at the maximum engine
The oil pump speed and at normal operating temperature is the
following value. ............................... 300 kPa (43 psi)
(1) Clearance of the outer rotor to the
body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch) i02506230
Engine Oil Pan
Table 5
Required Tools
Tool Part Number Part Description Qty
POWERPART
A 21826038 1
Retainer
g00938061
Illustration 33
Checking the clearance
(2) Clearance of inner rotor to outer

rotor ...................................... 0.040 to 0.127 mm
(0.0015 to 0.0050 inch)
g00938799
Illustration 34
Checking the end play
18 RENR8913
Front sealant ApplyTooling (A) to the bridge. The sealant must not
protrude more than 5 mm (0.1969 inch) above the
bridge.
g01254690
Illustration 35
Applying sealant
Apply Tooling (A) to the cylinder block and to the

timing case.
Note: Apply a sealant bead of 3.5 mm (0.1378 inch)

that is shown in illustration 35.
g01255016
Illustration 37
Rear sealant Typical example
Note: Install the rear oil seal before sealant is applied (1) Tighten the four front bolts in position (X) to the
to the bridge. following torque. ....................... 22 N·m (16 lb ft)
Tighten the remaining bolts to the following

torque. ............................................. 22 N·m (16 lb ft)
(2) Drain plug

Tighten the drain plug for the engine oil pan to
the following torque. ................. 34 N·m (25 lb ft)
g01254887
Illustration 36
Applying sealant
RENR8913 19
i02505676 Installed in the Balancer

Engine Oil Bypass Valve
Installed in the Oil Pump
g00919890
Illustration 40
Plug
g00919893
Illustration 38
Typical engine oil pump
g00921379
Illustration 41
The relief valve for the balancer
(1) Tighten the plug for the relief valve to the

following torque. ....................... 35 N·m (26 lb ft)
(2) Plunger
Illustration 39
g00921377 Diameter of the plunger ........ 14.46 to 14.48 mm
Relief valve and spring
(0.5692 to 0.5700 inch)
Clearance of the plunger in the
(1) Tighten the plug for the relief valve to the bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch)
(3) Spring
(2) Plunger
Length of the spring ........... 67 mm (2.6378 inch)
Diameter of the plunger ..... 19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)
(3) Spring
Length of the spring ...... 80.94 mm (3.1866 inch)
20 RENR8913
i02527053 Breather Canister

Crankcase Breather
Open crankcase breather
g01277901
Illustration 42
Typical example
(1) Connection
(2) Clamp
(3) Hose
(4) Clip g01277902
Illustration 43
Typical example
(2) Tighten the clamp to the following torque. .. 5 N·m
(1) Connection
(44 lb in) (2) Clamp
(3) Hose
(4) Filter base
(5) Bolts
(6) Clamp
(7) Hose
(8) Canister
(5) Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)
(2) Tighten the clamps to the following

torque. ........................................ 3 N·m (26 lb in)
(6) Tighten the clamp to the following torque. .. 3 N·m

(26 lb in)
(8) Tighten the canister to the following

torque. .................................... 12 N·m (106 lb in)
RENR8913 21
i02504533 i02363605
Water Temperature Regulator Water Pump

and Housing
Table 6
Required Tools
POWERPART Red
A 21820221 1
Rubber Grease
g01183807
Illustration 45
Tightening sequence
Tighten the setscrews in the numerical sequence

that is shown in illustration 45 to the following
torque. ............................................. 22 N·m (16 lb ft)
g01253716
Illustration 44
Typical example
Note: Apply Tooling (A) to the O-ring (4) in order to

install the water temperature regulator housing (2).
(1) Tighten the bolts that fasten the housing to the

(2) Water temperature regulator housing
(3) Water temperature regulator

Opening temperature ........................ 82° to 87°C
(179.6000° to 156.6000°F)
Full opening temperature .... 95 °C (203.0000 °F)
Minimum stroke at full temperature ........... 9 mm
(0.3543 inch)
22 RENR8913
i02505673 Diameter of the bore in the cylinder

block for the number 2 camshaft
Cylinder Block journal ............................... 50.546 to 50.597 mm
(1.9900 to 1.9920 inch)
Diameter of the bore in the cylinder
journal ............................... 50.038 to 50.089 mm
(1.9700 to 1.9720 inch)
(4) Main bearings

Bore in the cylinder block for the main
bearings ............................ 88.246 to 88.272 mm
(3.4742 to 3.4753 inch)
Install the main bearing cap bolts (5). Refer to

Disassembly and Assembly, “Crankshaft Main
Bearings - Remove and Install” or Disassembly
and Assembly, “Crankshaft - Install” for the correct
procedure.
(5) Main bearing cap bolts

Evenly tighten the main bearing cap bolts. Torque
for the main bearing cap bolts. .. 80 N·m (59 lb ft)
Note: Tighten the bolts for the main bearing cap for
an additional 90 degrees.
Note: Ensure that the crankshaft can rotate freely.
g01254475
Illustration 46
Cylinder block
(1) Cylinder block
(2) Cylinder bore ................ 105.000 to 105.025 mm

(4.1338 to 4.1348 inch)
The first oversize bore

diameter .................................. 105.5 to 105.525 mm
(4.1535 to 4.1545 inch)
The second oversize bore

diameter .............................. 106.000 to 106.025 mm
(4.1732 to 4.1742 inch)
The maximum permissible wear for the cylinder

bore ....................................... 0.15 mm (0.0059 inch)
(3) Camshaft bearings

Diameter of the bushing in the cylinder
bearing .............................. 55.563 to 55.593 mm
(2.1875 to 2.1887 inch)
RENR8913 23
i02506995
Crankshaft
g01255050
Illustration 47
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
Maximum permissible temperature of the gear for

installation on the crankshaft ........... 180 °C (356 °F)
The end play of a new crankshaft ... 0.16 to 0.38 mm

(0.0063 to 0.0150 inch)
Standard thickness of thrust

washer ...... 2.26 to 2.31 mm (0.0890 to 0.0909 inch)
Oversize thickness of thrust

washer ...... 2.45 to 2.50 mm (0.0965 to 0.0984 inch)
24 RENR8913
g01261588
Illustration 48
Typical example
Table 7
The Undersize Diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.926 to 75.905 mm 75.672 to 75.651 mm 75.418 to 75.397 mm
1
(2.9892 to 2.9884 inch) (2.9792 to 2.9784 inch) (2.9692 to 2.9684 inch)
63.236 to 63.216 mm 62.982 to 62.962 mm 62.728 to 62.708 mm
2
(2.4896 to 2.4888 inch) (2.4796 to 2.4788 inch) (2.4696 to 2.4688 inch)
40.551 mm (1.5965 inch)
3 N/A N/A
maximum
39.47 mm (1.5539 inch)
4 N/A N/A
maximum
39.47 mm (1.5539 inch)
5 N/A N/A
maximum
44.68 mm (1.7591 inch)
6 N/A N/A
maximum
7 Do not machine this diameter. Do not machine this diameter. Do not machine this diameter.
Item (6) in table 7 can be repaired with a crankshaft Table 8

wear sleeve. Refer to Disassembly and Assembly, Minimum Width of machined Area of Crankshaft Web
“Crankshaft Wear Sleeve (Rear) - Remove and
Install” for more information. Web 1, 2, 3, 6 4 and 5 8
and 7
18.31 mm 19.11 mm 26.61 mm
(0.7209 (0.7524 (1.0476
inch) inch) inch)
RENR8913 25
If necessary, machine the thrust face in order to Refer to Specifications, “Connecting Rod Bearing
remove damage. Refer to table 8 for information. Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.
Refer to table 9 for the run out of the crankshaft
journals. Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and for
Table 9 information on the main bearings.
Journal Run out of the Journals
(1) Mounting i02504536
(2) 0.08 mm (0.0031 inch) Crankshaft Seals

(3) 0.15 mm (0.0059 inch)
(4) 0.08 mm (0.0031 inch)
(5) Mounting
The radii of all the crankshaft journals must be

machined. This machining must return the crankshaft
to the original standard. The radii must give a smooth
transition from the journal to the side machined face.
g01253721
Illustration 50
Typical example
(1) Crankshaft
(2) Crankshaft seal

g01261590
Illustration 49
Typical example (3) Plastic sleeve
The edge of the oil holes (4) must be machined to the (4) Alignment tool
original standard after machining of the crankshaft.
Oil hole
The maximum radius of the edge of the oil
hole ................................... 0.5 mm (0.0197 inch)
Surface finish of all journals .............. Ra 0.2 microns
Surface finish of all radii .................... Ra 0.4 microns
Inspect the crankshaft for structural cracking after

machining.
26 RENR8913
(1) Tighten the three bolts for the crankshaft pulley

to the following torque. ............ 115 N·m (85 lb ft)
Note: Recheck the torque of the bolts (1) once.
(2) Thrust block
(3) Crankshaft pulley
Crankshaft Pulley for the Poly

V-Belt
g00915076
Illustration 51
(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the

sequence that is shown in Illustration 51 to the
Remove the alignment tool.
Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 51 to the following torque. ........ 22 N·m
(16 lb ft)
g01254970
Illustration 53
i02506934
Typical example
Crankshaft Pulley (1) Bolt
(2) Thrust block
(3) Crankshaft adapter
(5) Bolt
(1) Tighten the three bolts for the thrust block to the
following torque. ...................... 115 N·m (85 lb ft)
Note: Recheck the torque of the bolts (1) once.
(5) Tighten the three bolts for the crankshaft pulley

to the following torque. ............. 78 N·m (58 lb ft)
g00915497
Illustration 52
A standard pulley
Note: Lubricate the threads of the bolts with clean

engine oil before installation.
RENR8913 27
i02504771 Surface finish of radii .............................. 1.3 microns

Connecting Rod Bearing Width of new main bearing
Journal journal ... 39.34 to 39.24 mm (1.5488 to 1.5449 inch)
Width of new center main bearing

journal ... 44.22 to 44.15 mm (1.7409 to 1.7382 inch)
The shell for the main bearings

The shells for the main bearings are available
for remachined journals which have the following
Refer to Specifications, “Crankshaft” for information undersize dimensions.
on the undersize crankshaft journals.
Undersize bearing shell .... 0.25 mm (0.010 inch)
Undersize bearing shell .... 0.51 mm (0.020 inch)
The original size of the connecting rod bearing Undersize bearing shell .. 0.76 mm (0.0299 inch)
journal ... 63.47 to 63.49 mm (2.4988 to 2.4996 inch)
Thickness at center of the shells .. 2.083 to 2.089 mm
Maximum permissible wear of a bearing journal on a (0.0820 to 0.0823 inch)
new connecting rod .............. 0.04 mm (0.0016 inch)
Width of the main bearing shells .. 31.62 to 31.88 mm
Width of the connecting rod bearing (1.244 to 1.255 inch)
journals ................................... 40.348 to 40.424 mm
(1.5885 to 1.5915 inch)
Clearance between the bearing shell and the main
bearing journals ........................... 0.117 to 0.058 mm
Radius of the fillet of the connecting rod bearing
(0.0046 to 0.0023 inch)
journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)
Surface finish of connecting rod bearing i02505708

journals ............................................ Ra 0.4 microns
Connecting Rod
Surface finish of radii ....................... Ra 1.3 microns
i02506007
Main Bearing Journal
Refer to Specifications, “Crankshaft” for information

on the undersize main bearing journals, and
information on the width of main bearing journals.
The original size of the main bearing

journal ..................................... 76.180 to 76.159 mm
(2.9992 to 2.9984 inch)
Maximum permissible wear of the main bearing Illustration 54

g01254512
journals ............................... 0.040 mm (0.0016 inch)
Typical example
Radius of the fillet of the main bearing

journals ..... 3.68 to 3.69 mm (0.1448 to 0.1452 inch) (1) The bearing shell for the connecting rod
Surface finish of bearing journals and crank pins

................................................................ 0.4 microns
28 RENR8913
Table 10
Thickness of Connecting
1.8352 to 1.8415 mm
Rod Bearing at the
(0.0723 to 0.0725 inch)
Center
Thickness of Connecting
1.8352 to 1.8415 mm
Rod Bearing for the Cap
(0.0723 to 0.0725 inch)
at the Center
0.034 ± 0.081 mm
Bearing Clearance
(0.0013 ± 0.0032 inch)
Table 11
Undersized Connecting Rod Bearing
0.25 mm (0.010 inch)

0.51 mm (0.020 inch)
0.76 mm (0.030 inch)
The mating surfaces of the connecting rod are

produced by hydraulically fracturing the forged
connecting rod.
(2) Tighten the setscrews for the connecting rod to

the following torque. ................. 18 N·m (13 lb ft)
Tighten the setscrews for the connecting rod again to g01254518

the following torque. ........................ 70 N·m (52 lb ft) Illustration 55
Typical example
Tighten the setscrews for the connecting rod for
an additional 120 degrees. The setscrews for the (3) Diameter of the finished bore for the piston
connecting rod (2) must be replaced after this pin ..................................... 39.738 to 39.723 mm
procedure. (1.5645 to 1.5639 inch)
Note: Always tighten the connecting rod cap to the (4) Distance between the parent bores
connecting rod, when the assembly is out of the ...... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft). (5) Diameter for the finished bore for the connecting
rod bearing ....................... 67.208 to 67.221 mm
(2.6460 to 2.6465 inch)
g00915056
Illustration 56
RENR8913 29
Connecting rods are color coded. The color code Note: When you install a new top compression ring,
is a reference for the length (Y) of the connecting make sure that the word “TOP” is facing the top
rod. Refer to table 12 for the different lengths of of the piston. New top piston rings have a yellow
connecting rods. identification mark which must be on the left of the
ring end gap when the top piston ring is installed on
Table 12 an upright piston.
Length Grades for Connecting Rods
(2) Intermediate compression ring
Grade Letter Color Code Length (Y)
The shape of the intermediate compression
165.761 to 165.728 mm
F Red
(6.5260 to 6.5247 inch)
ring ....................................... Internal bevel in the
bottom edge with a tapered face
165.715 to 165.682 mm
G Orange Width of intermediate compression
(6.5242 to 6.5229 inch)
ring .... 2.47 to 2.495 mm (0.0972 to 0.0982 inch)
165.670 to 165.637 mm
H White
(6.5224 to 6.5211 inch) The clearance between a new intermediate
165.624 to 165.591 mm compression ring and the piston groove in a new
J Green piston ..................................... 0.065 to 0.011 mm
(6.5206 to 6.5193 inch)
(0.0026 to 0.0004 inch)
165.578 to 165.545 mm
K Purple
(6.5188 to 6.5175 inch) Ring gap ................................... 0.65 to 0.85 mm
165.532 to 165.499 mm
(0.0256 to 0.0335 inch)
L Blue
(6.5170 to 6.5157 inch)
Note: When you install a new intermediate
compression ring, make sure that the word “TOP” is
i02363087
facing the top of the piston. New intermediate rings
have a blue identification mark which must be on the
Piston and Rings left of the ring end gap when the top piston ring is
installed on an upright piston.
(3) The oil control ring

Width of oil control ring ............. 2.97 to 2.99 mm
(0.1169 to 0.1177 inch)
The clearance between a new oil control ring and
the groove in a new piston ........ 0.03 to 0.07 mm
(0.0011 to 0.0027 inch)
Ring gap ................................... 0.30 to 0.55 mm
(0.0118 to 0.0216 inch)
Note: The oil control ring is a two-piece ring that is

spring loaded. 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
installed opposite the end gap of the oil control ring.
Note: Ensure that the ring end gaps of the piston

rings are spaced 120 degrees from each other.
Illustration 57
g01155119 Piston
Typical example Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
(1) Top compression ring
Piston height above cylinder block .. 0.21 to 0.35 mm
The shape of the top compression ring .. tapered
(0.008 to 0.014 inch)
Ring gap ................................... 0.30 to 0.45 mm
(0.0118 to 0.0177 inch) Width of top groove in the piston ................. Tapered
Width of second groove in new

piston ........ 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
30 RENR8913
Width of third groove in new piston .. 3.02 to 3.04 mm Piston Cooling Jet Alignment
(0.1189 to 0.1197 inch)
Piston pin
Diameter of a new piston
pin ..................................... 39.694 to 39.700 mm
(1.5628 to 1.5630 inch)
Oversize Piston
Table 13
Standard piston
1 Oversize +0.5 mm (0.0197 inch) piston
2 Oversize +1.0 mm (0.0394 inch) piston g01006929
Illustration 59
(2) Piston cooling jet
(3) Rod
i02367100 (4) Cylinder block
Piston Cooling Jet Use the following procedure in order to check the
alignment of the piston cooling jet.
1. Insert rod (3) into the end of the piston cooling

jet (2). Rod (3) has a diameter of 1.70 mm
(0.067 inch). Rod (3) must protrude out of the top
of the cylinder block.
2. Dimension (A) is 50.75 mm (1.9980 inch)

and dimension (B) is 9.35 mm (0.3681 inch).
Dimension (A) and dimension (B) are tangential
to the cylinder bore (4).
3. The position of the rod (3) must be within

dimension (C). Dimension (C) is 14 mm
(0.5512 inch).
Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
g00942652
Illustration 58 piston cooling jets can not be adjusted. If a piston
(1) Installed piston cooling jets cooling jet is not in alignment the piston cooling jet
must be replaced.
The valve must move freely. Tighten the bolt to the
following torque. .................................. 9 N·m (7 lb ft)
i02369751
Front Housing and Covers
The front housing must be aligned to the cylinder

block face. ......................... + 0.05 to minus 0.05 mm
(+ 0.0020 to minus 0.0020 inch )
RENR8913 31
g00995663 g00918672
Illustration 60 Illustration 62
Alignment Typical example
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
Note: Refer to Specifications, “Water Pump” for the

correct bolt tightening sequence for the water pump.
i02504717
Gear Group (Front)
g01203927
Illustration 61
Typical example
Tighten the setscrew to the sequence that is shown

in illustration 61 to the following torque. ......... 28 N·m
(20 lb ft)
(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
g00995886
Illustration 63
Gear train
32 RENR8913
(1) Fuel injection pump drive gear

Tighten the nut to the following torque. ... 25 N·m
(18 lb ft)
Release the lock on the fuel injection pump shaft.
Torque the nut to the following torque. .... 90 N·m
(66 lb ft)
Number of teeth .............................................. 68
Note: Refer to Specifications, “Fuel Injection Pump”

for the locking torque for the fuel injection pump shaft.
(2) Camshaft gear

Tighten the bolt for the camshaft gear to the g00996214
Illustration 64
The gear train for the oil pump
Number of teeth .............................................. 68
(4) Crankshaft gear
(3) Idler gear and hub
Bore diameter of crankshaft gear
Tighten the bolts for the idler gear to the following ........ 51.00 to 51.03 mm (2.0079 to 2.0091 inch)
torque. ...................................... 44 N·m (33 lb ft)
Outside diameter of crankshaft
Width of idler gear and split bearing hub .................................... 51.021 to 51.002 mm
assembly .......................... 30.165 to 30.135 mm (2.0087 to 2.0079 inch)
(1.1876 to 1.1864 inch)
Clearance of gear on
Inside diameter of idler gear bearings with crankshaft ......................... í0.021 to +0.028 mm
flanges .............................. 50.797 to 50.818 mm (í0.0008 to 0.0011 inch)
(1.9999 to 2.0007 inch)
Number of teeth .............................................. 34
Outside diameter of idler gear
hub .................................... 50.716 to 50.737 mm (5) Oil pump idler gear
(1.9967 to 1.9975 inch)
Inside diameter of oil pump idler gear
Clearance of idler gear bearing on bearing .............................. 16.012 to 16.038 mm
hub .... 0.06 to 0.102 mm (0.0024 to 0.0040 inch) (0.6304 to 0.6314 inch)
Idler gear end play .................. 0.13 to 0.205 mm Outside diameter of oil pump idler gear
(0.0051 to 0.0081 inch) shaft .................................. 15.966 to 15.984 mm
(0.6286 to 0.6293 inch)
Maximum permissible end play ............ 0.38 mm
(0.015 inch) Clearance of oil pump idler gear bearing on
shaft ...................................... 0.028 to 0.072 mm
Idler gear end play with roller (0.0011 to 0.0028 inch)
bearings .................................. 0.24 to 0.954 mm
(0.0094 to 0.0376 inch) End play of the oil pump idler
gear ...................................... 0.050 to 0.275 mm
Number of teeth .............................................. 73 (0.0019 to 0.0108 inch)
(6) Oil pump gear

The number of teeth on the oil pump gear ..... 17
Backlash values
Backlash between the idler gear (5) and the oil
pump drive gear (6) .................. 0.05 to 0.14 mm
(0.0020 to 0.0055 inch)
Backlash between the oil pump idler gear (5) and
the crankshaft gear (4) ............... 0.8 to 0.23 mm
(0.0315 to 0.0091 inch)
RENR8913 33
Backlash between the idler gear (3) and the (3) Bolt
crankshaft gear (4) ................. 0.05 to 0.015 mm
(0.0020 to 0.0006 inch) Tighten the flywheel bolts to the following
torque. ..................................... 115 N·m (85 lb ft)
Backlash between the camshaft gear (2) and the
idler gear (3) ............................. 0.05 to 0.15 mm
i02505674
(0.0020 to 0.0059 inch)
Backlash between the fuel injection pump gear Flywheel Housing
(1) and the idler gear (3) ........... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
Table 14
(1) ....... 0.05 to 0.15 mm (0.0020 to 0.0059 inch)
Backlash between the power take-off Required Tools
drive (if equipped) and the idler gear Tool Part Number Part Description Qty
(3) ..... 0.05 to 0.250 mm (0.0020 to 0.0098 inch)
POWERPART
A 21820117 Threadlock and 1
i02503254 Nutlock
Flywheel
g01254486
Illustration 66
Typical example
g00584712
Illustration 65
Typical example Setscrew
(1) Tighten the setscrew to the following
(1) Flywheel ring gear
torque. ................................ 75 N·m (55 lb ft)
Heat the flywheel ring gear to the following
temperature. .............................. 250 °C (480 °F) Setscrew
(2) Tighten the setscrew to the following
Note: Do not use an oxyacetylene torch to heat the
torque. ................................ 63 N·m (46 lb ft)
flywheel ring gear.
(2) Flywheel
34 RENR8913
Note: If 12.9 setscrews are installed, apply Tooling

(A) to the setscrews. Tighten the 12.9 setscrews to a
torque of 70 N·m (52 lb ft).
i02519438
Belt Tension Chart
Table 15
Required Tools
A - Belt Tension Gauge 1
Table 16
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
1/2 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free i02504537

length of belt and check the tension on both belts.
Check and adjust the tension on the tightest belt. Alternator
To adjust the belt tension, refer to Disassembly and
Assembly, “Alternator - Install”.
Note: A poly v-belt has an automatic belt tensioner.

No manual adjustment of the poly v-belt is required.
The 12 Volt Denso Alternator
To replace the poly v-belt, refer to Disassembly and
Assembly, “Alternator Belt - Remove and Install”. Six types of alternator are available.
Output
i01721280
Four 12 volt alternators are available. ... 75 Amp,
Engine Lifting Bracket 85 Amp, 100 Amp and 120 Amp
Two 24 volt alternators are
available. ........................... 55 Amp and 75 Amp
All engines are equipped with two engine lifting

brackets.
Tighten the two bolts on each engine lifting
bracket to the following torque. .. 44 N·m (32 lb ft)
RENR8913 35
The 24 Volt Iskra Alternator
g01194950
Illustration 67
g01194953
Typical example Illustration 68
Typical example
(1) Terminal “W”
(1) Terminal “B+”
Tighten the terminal nut to the following
torque. ..................................... 1.5 N·m (13 lb in) Tighten the terminal nut to the following
torque. ...................................... 11 N·m (97 lb in)
(2) Terminal “D+”
(2) Terminal “D+”
torque. ..................................... 1.5 N·m (13 lb in) Tighten the terminal nut to the following
torque. ........................................ 3 N·m (26 lb in)
(3) Terminal “B+”
(3) The terminal “W” is spade-type.
torque. ..................................... 3.3 N·m (29 lb in) 24 volt output
The 24 volt alternator ............................ 100 Amp
36 RENR8913
i02504538 12 Volt Starting Motor 3 Kw

Starter Motor
24 Volt Starting Motor 4.5 Kw
g01200844
Illustration 70
Typical example
(1) Tighten the nut for the positive terminal (terminal

30) to the following torque. ....... 6 N·m (53 lb in )
(2) Tighten the solenoid terminal (terminal 50) to the

g01200801
following torque. ........................ 8 N·m ( 70 lb in)
Illustration 69
Typical example (3) Tighten the nut for the terminal for the earth to
the following torque. ................ 8 N·m ( 70 lb in)
(1) Tighten the negative terminal nut to the following
torque. ....................................... 15 N·m (11 lb ft) Rated voltage ................................................ 12 volts
(2) Tighten the positive terminal nut to the following Pull in voltage ................................................. 8 volts
torque. ...................................... 21 N·m (15 lb ft)
(3) Tighten the solenoid terminal to the following

torque. ..................................... 3.5 N·m (31 lb in)
Rated voltage ................................................ 24 volts

RENR8913 37
i02371978 Ensure that all adjustments and repairs are performed

by personnel that have had the correct training.
Coolant Temperature Sensor
g01192226
Illustration 72
(1) Fuel pressure sensor
(2) Washer
Illustration 71
g01183334 Fuel pressure sensor
Typical example Tighten the fuel pressure sensor to the following
torque. ...................................... 34 N·m (25 lb ft)
(1) Sensor
Tighten the sensor to the following i02371981
torque. ....................................... 15 N·m (11 lb ft)
Engine Oil Pressure Sensor
i02388157
Fuel Pressure Sensor

Refer to the Operation and Maintenance manual,

“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
Note: Refer to Testing and Adjusting Manual

, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
g01183333
work on the fuel system. Illustration 73
Typical example
38 RENR8913
(1) Sensor i02493822
Tighten the sensor to the following torque. Inlet Manifold Temperature

.................................................... 10 N·m (7 lb ft)
Sensor
i02371977
Boost Pressure Sensor
g01183334
Illustration 75
Typical example
g01183333
(1) Sensor
Illustration 74
Typical example Tighten the sensor to the following
torque. ...................................... 20 N·m (15 lb ft)
(1) Sensor
Tighten the sensor to the following
torque. ........................................ 10 N·m (7 lb ft)
RENR8913 39
i02404840 i02506817
Crankshaft Position Sensor Electronic Control Module
g01201229 g01254910
Typical example (1) Electronic control module (ECM)
(2) Connectors
(3) Setscrew
(1) Tighten the bolt for the sensor to the following
(4) Setscrew
torque. ...................................... 22 N·m (16 lb ft)
(2) Connectors
Tighten the connectors to the following
torque. ................................... 18.5 N·m (14 lb ft)
(3) Setscrew
Tighten the setscrew to the following
torque. ........................................ 5 N·m (44 lb in)
(4) Setscrew
Tighten the setscrew to the following
torque. ...................................... 22 N·m (16 lb ft)
40 RENR8913
i02505941
Glow Plugs
g01254601
Illustration 78
Typical example
Tighten the glow plugs (2) in the cylinder head to the

following torque. ............................... 15 N·m (11 lb ft)
Tighten the nuts (1) for the bus bar (3) that is
installed on top of the glow plugs to the following
torque. ............................................... 2 N·m (18 lb in)
Voltage ................................................. 12 or 24 volts

RENR8913 41
Index Section
Index
A Fuel Injection Lines................................................ 4
Manifold to Injector............................................. 5
Alternator ............................................................... 34 Pump to Manifold ............................................... 5
The 12 Volt Denso Alternator............................. 34 Fuel Injection Pump............................................... 5
The 24 Volt Iskra Alternator ............................... 35 Fuel Injectors ......................................................... 6
Fuel Pressure Sensor............................................ 37
Fuel Priming Pump ................................................ 7
B Electric fuel Priming Pump................................. 7
Hand Fuel Priming Pump................................... 7
Belt Tension Chart ................................................. 34 Fuel Transfer Pump............................................... 6
Boost Pressure Sensor.......................................... 38
G
C
Gear Group (Front)................................................ 31
Camshaft ............................................................... 13 Glow Plugs ............................................................ 40
Camshaft Bearings ................................................ 13
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 27 I
Coolant Temperature Sensor................................. 37
Crankcase Breather............................................... 20 Important Safety Information ................................. 2
Breather Canister............................................... 20 Inlet Manifold Temperature Sensor........................ 38
Open crankcase breather .................................. 20
Crankshaft ............................................................ 23
Crankshaft Position Sensor ................................... 39 L
Crankshaft Pulley .................................................. 26
Crankshaft Pulley for the Poly V-Belt................. 26 Lifter Group............................................................ 7
Crankshaft Seals ................................................... 25
Cylinder Block........................................................ 22
Cylinder Head........................................................ 11 M
Cylinder Head Valves ............................................ 10
Main Bearing Journal............................................. 27
The shell for the main bearings.......................... 27
E
Electronic Control Module ..................................... 39 P

Engine Design ....................................................... 4
Engine Lifting Bracket............................................ 34 Piston and Rings ................................................... 29
Engine Oil Bypass Valve ....................................... 19 Oversize Piston.................................................. 30
Installed in the Balancer..................................... 19 Piston ................................................................. 29
Installed in the Oil Pump .................................... 19 Piston Cooling Jet.................................................. 30
Engine Oil Cooler .................................................. 15 Piston Cooling Jet Alignment ............................. 30
Engine Oil Filter Base............................................ 14
Engine Oil Pan....................................................... 17
Front sealant ...................................................... 18 R
Rear sealant....................................................... 18
Engine Oil Pressure............................................... 17 Rocker Shaft.......................................................... 8
Engine Oil Pressure Sensor .................................. 37
Engine Oil Pump.................................................... 15
Engines with Balancer Group ............................ 15 S
Engines without Balancer Group ....................... 16
Exhaust Manifold ................................................... 12 Specifications Section ........................................... 4
Starter Motor.......................................................... 36
12 Volt Starting Motor 3 Kw ............................... 36
F 24 Volt Starting Motor 4.5 Kw ............................ 36
Flywheel ................................................................ 33
Flywheel Housing .................................................. 33 T
Front Housing and Covers..................................... 30
Fuel Filter Base ..................................................... 7 Table of Contents................................................... 3
42 RENR8913
Index Section
Turbocharger ......................................................... 12
Valve Mechanism Cover........................................ 9
Water Pump........................................................... 21
Water Temperature Regulator and Housing .......... 21
RENR8913 43
Index Section
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
RENR7967
September 2006
Systems Operation
Testing and Adjusting
1104D Industrial Engine
NH (Engine)
NJ (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

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

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
RENR7967 3
Table of Contents
Table of Contents Gear Group - Inspect ............................................ 75

Crankshaft Pulley - Check .................................... 76
Electrical System
Systems Operation Section Alternator - Test .................................................... 78
Battery - Test ......................................................... 79
General Information
V-Belt - Test .......................................................... 79
Introduction ............................................................ 4
Charging System - Test ........................................ 80
Electric Starting System - Test .............................. 81
Engine Operation
Glow Plugs - Test .................................................. 83
Basic Engine ........................................................... 6
Air Inlet and Exhaust System ................................ 11
Cooling System .................................................... 14 Index Section
Lubrication System .............................................. 16
Electrical System ................................................. 17 Index ..................................................................... 84
Cleanliness of Fuel System Components ............. 18
Fuel Injection ....................................................... 20
Electronic Control System ................................... 27
Power Sources ..................................................... 36
Glossary of Electronic Control Terms ................... 39
Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 45
Air in Fuel - Test .................................................... 45
Finding Top Center Position for No. 1 Piston ........ 46
Fuel Injection Timing - Check ............................... 47
Fuel Quality - Test ................................................. 48
Fuel System - Prime ............................................. 49
Gear Group (Front) - Time .................................... 50
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 51
Turbocharger - Inspect .......................................... 52
Compression - Test ............................................... 55
Engine Valve Lash - Inspect/Adjust ...................... 56
Valve Depth - Inspect ............................................ 58
Valve Guide - Inspect ............................................ 59
Lubrication System
Engine Oil Pressure - Test .................................... 61
Engine Oil Pump - Inspect .................................... 61
Excessive Bearing Wear - Inspect ........................ 62
Excessive Engine Oil Consumption - Inspect ....... 62
Increased Engine Oil Temperature - Inspect ........ 63
Cooling System
Cooling System - Check ....................................... 64
Cooling System - Inspect ...................................... 64
Cooling System - Test ........................................... 65
Engine Oil Cooler - Inspect ................................... 66
Water Temperature Regulator - Test ..................... 67
Water Pump - Inspect ........................................... 68
Basic Engine
Piston Ring Groove - Inspect ................................ 69
Connecting Rod - Inspect ..................................... 69
Cylinder Block - Inspect ........................................ 72
Cylinder Head - Inspect ........................................ 72
Piston Height - Inspect .......................................... 72
Flywheel - Inspect ................................................. 73
Flywheel Housing - Inspect ................................... 74
4 RENR7967
Systems Operation Section
General Information
i02517251
Introduction
The following model views show a typical 1104D

engine. Due to individual applications, your engine
may appear different from the illustrations.
g01245941
Illustration 1
Front left engine view
(1) Front lifting eye (6) Oil gauge (11) Crankshaft pulley
(2) Water outlet (7) Secondary fuel filter (12) Water pump
(3) Rear lifting eye (8) Oil filler (13) Belt tensioner
(4) Fuel manifold (rail) (9) Oil sampling valve
(5) Electronic control module (10) Oil filter
RENR7967 5
g01245940
Illustration 2
Rear right engine view
(14) Turbocharger (18) Starting motor (22) Hand fuel priming pump
(15) Alternator (19) Oil pan (23) Flywheel housing
(16) Exhaust manifold (20) Drain plug (24) Heat shield
(17) Wastegate solenoid (21) Primary fuel filter
Note: The primary fuel filter is mounted off the Each cylinder has a piston cooling jet that is installed
engine. in the cylinder block. The piston cooling jet sprays
engine oil onto the inner surface of the piston in order
The 1104D models NH1 and NJ1 diesel engines are to cool the piston. The pistons have a Quiescent
electronically controlled. The 1104D engine uses combustion chamber in the top of the piston in order
an Electronic Control Module (ECM) that receives to achieve clean exhaust emissions. The piston pin is
signals from the fuel injection pump and other off-center in order to reduce the noise level.
sensors in order to control the fuel injectors. The
pump supplies fuel to the fuel injectors. The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
The four cylinders are arranged in-line. The cylinder metal insert in order to reduce wear of the groove.
head assembly has two inlet valves and two exhaust The skirt has a coating of graphite in order to reduce
valves for each cylinder. The ports for the exhaust wear when the engine is new. The correct piston
valves are on the right side of the cylinder head. The height is important in order to ensure that the piston
ports for the inlet valves are on the left side of the does not contact the cylinder head. The correct
cylinder head. Each cylinder valve has a single valve piston height also ensures the efficient combustion
spring. of fuel which is necessary in order to conform to
requirements for emissions.
6 RENR7967
A piston and a connecting rod are matched to The fuel injection pump (1) that is installed on the
each cylinder. The piston height is controlled by the left side of the engine is gear-driven from the timing
distance between the center of the big end bearing case. The fuel transfer pump (25) is attached to the
and the center of the small end bearing of the fuel injection pump (1). The fuel transfer pump draws
connecting rod. Three different lengths of connecting low pressure fuel from the primary fuel filter. The
rods are available in order to attain the correct piston fuel transfer pump delivers the fuel to the secondary
height. The three different lengths of connecting rods filter at a pressure of 400 kPa (58 psi) to 500 kPa
are made by machining the blank small end bearing (72.5200 psi). The fuel injection pump draws fuel
of each rod at three fixed distances vertically above from the secondary filter. The fuel injection pump
the centerline of the big end bearing. . increases the fuel to a maximum pressure of 130 MPa
(18855 psi). The fuel injection pump delivers the fuel
The crankshaft has five main bearing journals. End to the fuel manifold. The fuel injection pump is not
play is controlled by thrust washers which are located serviceable. Adjustments to the pump timing should
on both sides of the number three main bearing. only be made by personnel that have had the correct
training. The fuel injection pump uses the engine
The timing case is made of aluminum. The timing ECM to control the engine RPM.
gears are stamped with timing marks in order to
ensure the correct assembly of the gears. When the The specifications for the 1104D refer to the
number 1 piston is at the top center position on the Specifications, “Engine Design”.
compression stroke, the marked teeth on the idler
gear will match with the marks that are on the fuel
injection pump, the camshaft, and the gear on the
crankshaft. There is no timing mark on the rear face Engine Operation
of the timing case.
i02525716
The crankshaft gear turns the idler gear which then
turns the following gears: Basic Engine
• the camshaft gear
Introduction (Basic Engine)
• the fuel injection pump
The eight major mechanical components of the basic
The camshaft and the fuel injection pump run at half engine are the following parts:
the rpm of the crankshaft. The cylinder bores are
machined into the cylinder block. • Cylinder block
• Cylinder head
• Pistons
• Connecting rods
• Crankshaft
• Timing gear case and gears
• Camshaft
• Rocker shaft assembly
g01259333
Illustration 3
RENR7967 7
Cylinder Block and Cylinder Head Cylinder head
g01263698 g01263700
Typical Cylinder Block Typical cylinder head
The cast iron cylinder block for the 1104D engine The engine has a cast iron cylinder head. The inlet
has four cylinders which are arranged in-line. The manifold is integral within the cylinder head. There
cylinder block is made of cast iron in order to provide are two inlet valves and two exhaust valve for each
support for the full length of the cylinder bores. Worn cylinder. Each pair of valves are connected by a valve
cylinders may be rebored in order to accommodate bridge that is controlled by a pushrod valve system.
oversize pistons and rings. The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves
The cylinder block has five main bearings which are on the right side of the cylinder head. The valve
support the crankshaft. Thrust washers are installed stems move in valve guides that are machined into
on both sides of number three main bearing in order the cylinder head. There is a renewable valve stem
to control the end play of the crankshaft. seal that fits over the top of the valve guide.
Passages supply the lubrication for the crankshaft

bearings. These passages are cast into the cylinder
block.
The cylinders are honed to a specially controlled

finish in order to ensure long life and low oil
consumption.
The cylinder block has a bush that is installed for the

front camshaft journal. The other camshaft journals
run directly in the cylinder block.
The engine has a cooling jet that is installed in the

cylinder block for each cylinder. The piston cooling
jet sprays lubricating oil onto the inner surface of the
piston in order to cool the piston.
A multi-layered steel (MLS) cylinder head gasket is

used between the engine block and the cylinder head
in order to seal combustion gases, water, and oil.
8 RENR7967
Pistons, Rings and Connecting The connecting rods are machined from forged
molybdenum steel. The connecting rods have
Rods bearing caps that are fracture split. The bearing caps
on fracture split connecting rods are retained with
Torx screws. Connecting rods with bearing caps that
are fracture split have the following characteristics:
• The splitting produces an accurately matched

surface on each side of the fracture for improved
strength.
Crankshaft
g01263701
Illustration 6
Typical example
The pistons have a Quiescent combustion chamber Illustration 7

g01263702
in the top of the piston in order to provide an efficient
mix of fuel and air. The piston pin is off-center in The crankshaft is a chromium molybdenum forging.
order to reduce the noise level. The crankshaft has five main journals. Thrust
washers are installed on both sides of number three
The pistons have two compression rings and an oil main bearing in order to control the end play of the
control ring. The groove for the top ring has a hard crankshaft.
metal insert in order to reduce wear of the groove.
The piston skirt has a coating of graphite in order to The crankshaft changes the linear energy of the
reduce the risk of seizure when the engine is new. pistons and connecting rods into rotary torque in
order to power external equipment.
The correct piston height is important in order to
ensure that the piston does not contact the cylinder A gear at the front of the crankshaft drives the timing
head. The correct piston height also ensures the gears. The crankshaft gear turns the idler gear which
efficient combustion of fuel which is necessary in then turns the following gears:
order to conform to requirements for emissions.
• Camshaft gear
• Fuel injection pump and fuel transfer pump
RENR7967 9
• Lower idler gear which turns the gear of the The camshaft and the fuel injection pump rotate at
lubricating oil pump. half the engine speed.
Lip type seals are used on both the front of the

crankshaft and the rear of the crankshaft.
Camshaft
A timing ring is installed to the crankshaft. The timing

ring is used by the ECM in order to measure the
engine speed and the engine position.
g01263706
Illustration 10
The engine has a single camshaft. The camshaft

is made of cast iron. The camshaft lobes are chill
g01263703
hardened.
Illustration 8
The camshaft is driven at the front end. As the
Gears and Timing Gear Case camshaft turns, the camshaft lobes move the valve
system components. The valve system components
move the cylinder valves.
The camshaft gear must be timed to the crankshaft

gear. The relationship between the lobes and the
camshaft gear causes the valves in each cylinder to
open at the correct time. The relationship between
the lobes and the camshaft gear also causes the
valves in each cylinder to close at the correct time.
g01263705
Illustration 9
The crankshaft oil seal is mounted in the aluminum

timing case. The timing case cover is made from
pressed steel.
The timing gears are made of steel.
The crankshaft gear drives an upper idler gear and

a lower idler gear. The upper idler gear drives the
camshaft and the fuel injection pump. The lower idler
gear drives the oil pump. The water pump drive gear
is driven by the fuel injection pump gear.
10 RENR7967
Rocker Shaft Assembly
g01263708
Illustration 11
The camshaft has two camshaft lobes for each

cylinder. The lobes operate either a pair of inlet
valves or a pair of exhaust valves. As the camshaft
turns, lobes on the camshaft cause the lifter to move
the pushrod up and down. Upward movement of the
pushrod against rocker arm results in a downward
movement that acts on the valve bridge. This action
opens a pair of valves which compresses the valve
springs. When the camshaft has rotated to the
peak of the lobe, the valves are fully open. When
the camshaft rotates further, the two valve springs
under compression start to expand. The valve stems
are under tension of the springs. The stems are
pushed upward in order to maintain contact with the
valve bridge. The continued rotation of the camshaft
causes the rocker arm, the pushrods and the lifters
to move downward until the lifter reaches the bottom
of the lobe. The valves are now closed. The cycle is
repeated for all the valves on each cylinder.
RENR7967 11
i02526613
g01205681
Illustration 12
Air inlet and exhaust system
(1) Exhaust manifold (5) Aftercooler core (if equipped) (9) Air inlet from the air cleaner
(2) Electronic unit injector (6) Exhaust outlet (10) Inlet valve
(3) Glow plug (7) Turbine side of turbocharger (11) Exhaust valve
(4) Inlet manifold (8) Compressor side of turbocharger
The components of the air inlet and exhaust system Air is drawn in through the air cleaner into the air
control the quality of air and the amount of air that is inlet of the turbocharger (9) by the turbocharger
available for combustion. The air inlet and exhaust compressor wheel (8). The air is compressed and
system consists of the following components: heated to about 150 °C (300 °F) before the air is
forced to the aftercooler (5). As the air flows through
• Air cleaner the aftercooler the temperature of the compressed
air lowers to about 50 °C (120 °F). Cooling of the
• Turbocharger inlet air increases combustion efficiency. Increased
combustion efficiency helps achieve the following
• Aftercooler benefits:
• Inlet manifold • Lower fuel consumption

• Cylinder head, injectors and glow plugs • Increased horsepower output
• Valves and valve system components • Reduced particulate emission
• Piston and cylinder From the aftercooler, air is forced into the inlet
manifold (4). Air flow from the inlet manifold to the
• Exhaust manifold cylinders is controlled by inlet valves (10). There are
two inlet valves and two exhaust valves for each
cylinder. The inlet valves open when the piston
moves down on the intake stroke. When the inlet
valves open, cooled compressed air from the inlet
port is forced into the cylinder. The complete cycle
consists of four strokes:
• Inlet
• Compression
12 RENR7967
• Power Turbocharger
• Exhaust
On the compression stroke, the piston moves back
up the cylinder and the inlet valves (10) close. The
cool compressed air is compressed further. This
additional compression generates more heat.
Note: If the cold starting system is operating, the

glow plugs (3) will also heat the air in the cylinder.
Just before the piston reaches the TC position, the

ECM operates the electronic unit injector. Fuel is
injected into the cylinder. The air/fuel mixture ignites.
The ignition of the gases initiates the power stroke.
Both the inlet and the exhaust valves are closed
and the expanding gases force the piston downward
toward the bottom center (BC) position .
From the BC position, the piston moves upward.

This initiates the exhaust stroke. The exhaust valves
open. The exhaust gases are forced through the g01263770
Illustration 13
open exhaust valves into the exhaust manifold.
Turbocharger
Exhaust gases from exhaust manifold (1) enter the (1) Air intake
turbine side of the turbocharger in order to turn (2) Compressor housing
(3) Compressor wheel
turbocharger turbine wheel (7). The turbine wheel is (4) Bearing
connected to the shaft that drives the compressor (5) Oil inlet port
wheel. Exhaust gases from the turbocharger pass (6) Bearing
through exhaust outlet (6), a silencer and an exhaust (7) Turbine housing
pipe. (8) Turbine wheel
(9) Exhaust outlet
(10) Oil outlet port
(11) Exhaust inlet
The turbocharger is mounted on the outlet of the

exhaust manifold in one of two positions on the right
side of the engine, toward the top of the engine or
to the side of the engine. The exhaust gas from
the exhaust manifold enters the exhaust inlet (11)
and passes through the turbine housing (7) of the
turbocharger. Energy from the exhaust gas causes
the turbine wheel (8) to rotate. The turbine wheel is
connected by a shaft to the compressor wheel (3).
As the turbine wheel rotates, the compressor

wheel is rotated. This causes the intake air to be
pressurized through the compressor housing (2) of
the turbocharger.
RENR7967 13
If a wastegate solenoid (15) is installed, then the

wastegate is controlled by the engine Electronic
Control Module (ECM). The ECM uses inputs from a
number of engine sensors to determine the optimum
boost pressure. This will achieve the best exhaust
emissions and fuel consumption at any given engine
operating condition. The ECM controls the solenoid
valve, which regulates the boost pressure to the
wastegate actuator.
When high boost pressure is needed for the engine

performance, a signal is sent from the ECM to the
wastegate solenoid . This causes low pressure in
the air inlet pipe (14) to act on the diaphragm within
the wastegate actuator (13). The actuating rod (12)
acts upon the actuating lever to close the valve in
the wastegate. When the valve in the wastegate
is closed, more exhaust gas is able to pass over
the turbine wheel. This results in an increase in the
speed of the turbocharger.
When low boost pressure is needed for the engine

performance, a signal is sent from the ECM to the
wastegate solenoid. This causes high pressure in
the air inlet pipe (14) to act on the diaphragm within
the wastegate actuator (13). The actuating rod (12)
acts upon the actuating lever to open the valve in
the wastegate. When the valve in the wastegate is
g01287919
Illustration 14 opened, more exhaust gas from the engine is able to
Typical turbocharger with the wastegate bypass the turbine wheel, resulting in an decrease in
(12) Actuating lever the speed of the turbocharger.
(13) Wastegate actuator
(14) Line (boost pressure) The shaft that connects the turbine to the compressor
(15) Wastegate solenoid wheel rotates in bearings (4 and 6). The bearings
require oil under pressure for lubrication and cooling.
When the load on the engine increases, more fuel The oil that flows to the lubricating oil inlet port (5)
is injected into the cylinders. The combustion of passes through the center of the turbocharger which
this additional fuel produces more exhaust gases. retains the bearings. The oil exits the turbocharger
The additional exhaust gases cause the turbine and from the lubricating oil outlet port (10) and returns
the compressor wheels of the turbocharger to turn to the oil pan.
faster. As the compressor wheel turns faster, air is
compressed to a higher pressure and more air is
forced into the cylinders. The increased flow of air
into the cylinders allows the fuel to be burnt with
greater efficiency. This produces more power.
A wastegate is installed on the turbine housing of

the turbocharger. The wastegate is a valve that
allows exhaust gas to bypass the turbine wheel of
the turbocharger. The operation of the wastegate is
dependent on the pressurized air (boost pressure)
from the turbocharger compressor. The boost
pressure acts on a diaphragm that is spring loaded
in the wastegate actuator which varies the amount of
exhaust gas that flows into the turbine.
14 RENR7967
Valve System Components The camshaft has two camshaft lobes for each
cylinder. The lobes operate either a pair of inlet
valves or a pair of exhaust valves. As the camshaft
turns, lobes on the camshaft cause the lifter (4)
to move the pushrod (3) up and down. Upward
movement of the pushrod against rocker arm (2)
results in a downward movement that acts on the
valve bridge (1). This action opens a pair of valves
(6) which compresses the valve springs (5). When
the camshaft has rotated to the peak of the lobe, the
valves are fully open. When the camshaft rotates
further, the two valve springs (5) under compression
start to expand. The valve stems are under tension of
the springs. The stems are pushed upward in order
to maintain contact with the valve bridge (1). The
continued rotation of the camshaft causes the rocker
arm (2), the pushrods (3)and the lifters (4) to move
downward until the lifter reaches the bottom of the
lobe. The valves (6) are now closed. The cycle is
repeated for all the valves on each cylinder.
i02527637
g01191272
Illustration 15
Valve system components
Cooling System
(1) Bridge
(2)
(3)
Rocker arm
Pushrod
Introduction (Cooling System)
(4) Lifter
(5) Spring The cooling system has the following components:
(6) Valve
• Radiator
The valve system components control the flow of
inlet air into the cylinders during engine operation. • Water pump
The valve system components also control the flow
of exhaust gases out of the cylinders during engine • Cylinder block
operation.
• Oil cooler
The crankshaft gear drives the camshaft gear through
an idler gear. The camshaft must be timed to the • Cylinder head
crankshaft in order to get the correct relation between
the piston movement and the valve movement. • Water temperature regulator (thermostat)
RENR7967 15
Coolant Flow
g01264578
Illustration 16
Coolant flow
(1) Radiator (6) Water temperature regulator (thermostat)
(2) Water pump and housing
(3) Cylinder block (7) Bypass for the water temperature
(4) Engine oil cooler regulator (thermostat)
(5) Cylinder head
The coolant flows from the bottom of the radiator (1)

to the centrifugal water pump (2). The water pump
(2) is installed on the front of the timing case. The
water pump is driven by a gear. The gear of the fuel
injection pump drives the water pump gear. The
water pump forces the coolant through a passage in
the timing case to the front of the cylinder block (3).
The coolant enters a passage in the left side of the

cylinder block (3). Some coolant enters the cylinder
block. Some coolant passes over the element of the
oil cooler (4). The coolant then enters the block (3).
Coolant flows around the outside of the cylinders
then flows from the cylinder block into the cylinder
head (5).
The coolant flows forward through the cylinder

head (5). The coolant then flows into the housing
of the water temperature regulator (6). If the water
temperature regulator (6) is closed, the coolant goes
directly through a bypass (7) to the inlet side of the
water pump. If the water temperature regulator is
open, and the bypass is closed then the coolant flows
to the top of the radiator (1).
16 RENR7967
i02527751
Lubrication System
g01264620
Illustration 17
Flow diagram of the lubrication system
Lubricating oil from the oil pan flows through a The inner rotor has five lobes which mesh with the six
strainer and a pipe (9) to the suction side of the lobes of the outer rotor. When the pump rotates, the
engine oil pump (10). Pressure for the lubrication distance increases between the lobes of the outer
system is supplied by the oil pump. The crankshaft rotor and the lobes of the inner rotor in order to create
gear (13) drives a lower idler gear (12). The lower suction. When the distance decreases between the
idler gear drives the oil pump gear (11). The pump lobes, pressure is created.
has an inner rotor and an outer rotor. The axis of
rotation of the rotors are off-center relative to each The lubricating oil flows from the outlet side of the oil
other. There is an interference fit between the inner pump (10) through a passage to the oil filter head
rotor and the drive shaft. (7). The oil then flows from the oil filter head through
a passage to a plate type oil cooler. The oil cooler is
located on the left side of the cylinder block.
RENR7967 17
From the oil cooler, the oil returns through a passage Starting Motor
to the oil filter head. The oil then flows through a
bypass valve that permits the lubrication system
to function if the oil filter becomes blocked. Under
normal conditions, the oil then flows to the oil filter (8).
The oil flows from the oil filter through a passage that
is drilled across the cylinder block to the oil gallery
(4). The oil gallery is drilled through the total length
of the left side of the cylinder block. If the oil filter is
on the right side of the engine, the oil flows through
a passage that is drilled across the cylinder block to
the pressure gallery.
Lubricating oil from the oil gallery flows through

high pressure passages to the main bearings of
the crankshaft (5). Then, the oil flows through the
passages in the crankshaft to the connecting rod
bearing journals (6). The pistons and the cylinder
bores are lubricated by the splash of oil and the oil
mist.
Lubricating oil from the main bearings flows through

g01216877
passages in the cylinder block to the journals of the Illustration 18
camshaft. Then, the oil flows from the front journal Typical example
of the camshaft (2) at a reduced pressure to the 12 Volt Starting Motor
cylinder head. The oil then flows through the center (1) Terminal for connection of the ground cable
of the rocker shaft (1) to the rocker arm levers. The (2) Terminal 30 for connection of the battery cable
valve stems, the valve springs and the valve lifters (3) Terminal 50 for connection of the ignition switch
are lubricated by the splash and the oil mist.
The hub of the idler gear is lubricated by oil from the

oil gallery. The timing gears are lubricated by the
splash from the oil.
An external line supplies oil to the high pressure fuel

pump. The oil then flows through a return line into the
timing case and back to the oil pan.
Engines have piston cooling jets that are supplied

with oil from the oil gallery. The piston cooling jets
spray lubricating oil on the underside of the pistons in
order to cool the pistons.
i02403276
Electrical System
g01200801
The electrical system is a negative ground system. Illustration 19
Typical example
The charging circuit operates when the engine 24 Volt Starting Motor
is running. The alternator in the charging circuit (1) Terminal for connection of the ground
produces direct current for the electrical system. (2) Terminal 30 for connection of the battery cable
(3) Terminal 50 for connection of ignition switch
The starting motor turns the engine via a gear on the

engine flywheel. The starting motor speed must be
high enough in order to initiate a sustained operation
of the fuel ignition in the cylinders.
18 RENR7967
The starting motor has a solenoid. When the ignition The alternator is connected to the battery through
switch is activated, voltage from the electrical system the ignition switch. Therefore, alternator excitation
will cause the solenoid to move the pinion toward occurs when the switch is in the ON position.
the flywheel ring gear of the engine. The electrical
contacts in the solenoid close the circuit between the
i02406189
battery and the starting motor just before the pinion
engages the ring gear. This causes the starting motor
to rotate. This type of activation is called a positive
Cleanliness of Fuel System
shift. Components
When the engine begins to run, the overrunning
clutch of the pinion drive prevents damage to the
armature. Damage to the armature is caused by Cleanliness of the Engine
excessive speeds. The clutch prevents damage by
stopping the mechanical connection. However, the
pinion will stay meshed with the ring gear until the NOTICE
ignition switch is released. A spring in the overrunning It is important to maintain extreme cleanliness when
clutch returns the clutch to the rest position. working on the fuel system, since even tiny particles
can cause engine or fuel system problems.
Alternator
The entire engine should be washed with a high
The electrical outputs of the alternator have the pressure water system in order to remove dirt and
following characteristics: loose debris before starting a repair on the fuel
system.
• Three-phase
Environment
• Full-wave
When possible, the service area should be positively
• Rectified pressurized in order to ensure that the components
are not exposed to contamination from airborne dirt
The alternator is an electro-mechanical component.
and debris. When a component is removed from
The alternator is driven by a belt from the crankshaft
the system, the exposed fuel connections must be
pulley. The alternator charges the storage battery
closed off immediately with suitable sealing plugs.
during the engine operation.
The sealing plugs should only be removed when
the component is reconnected. The sealing plugs
The alternator is cooled by an external fan which is
must not be reused. Dispose of the sealing plugs
mounted behind the pulley. The fan may be mounted
immediately after use. Contact your nearest Perkins
internally. The fan forces air through the holes in the
dealer or your nearest approved Perkins distributor in
front of the alternator. The air exits through the holes
order to obtain the correct sealing plugs.
in the back of the alternator.
The alternator converts the mechanical energy and New Components

the magnetic field into alternating current and voltage.
This conversion is done by rotating a direct current High pressure lines are not reusable. New high
electromagnetic field on the inside of a three-phase pressure lines are manufactured for installation in
stator. The electromagnetic field is generated by one position only. When a high pressure line is
electrical current flowing through a rotor. The stator replaced, do not bend or distort the new line. Internal
generates alternating current and voltage. damage to the pipe may cause metallic particles to
be introduced to the fuel.
The alternating current is changed to direct current
by a three-phase, full-wave rectifier. Direct current All new fuel filters, high pressure lines, tube
flows to the output terminal of the alternator. The assemblies and components are supplied with
direct current is used for the charging process. sealing plugs. These sealing plugs should only
be removed in order to install the new part. If
A regulator is installed on the rear end of the the new component is not supplied with sealing
alternator. Two brushes conduct current through two plugs then the component should not be used.
slip rings. The current then flows to the rotor field. A The technician must wear suitable rubber gloves.
capacitor protects the rectifier from high voltages. The rubber gloves should be disposed of immediately
after completion of the repair in order to prevent
contamination of the system.
RENR7967 19
Refueling
In order to refuel the diesel fuel tank, the refueling
pump and the fuel tank cap assembly must be clean
and free from dirt and debris. Refueling should take
place only when the ambient conditions are free
from dust, wind and rain. Only use fuel, free from
contamination, that conforms to the specifications
in the Operation and Maintenance Manual, “Fluid
Recommendations” Fuel Specifications.
20 RENR7967
i02528870
Fuel Injection
Introduction (Fuel Injection)
g01236714
Illustration 20
Diagram of the basic fuel system (typical example)
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the fuel injection pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector
(3) Wastegate Valve (if equipped) (8) Fuel Manifold Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Injection Pump (10) Intake Manifold Temperature Sensor
RENR7967 21
Low Pressure Fuel System
g01265309
Illustration 21
Low pressure fuel system (typical example)
(1) Primary fuel filter (7) Fuel Injection Pump (D) Return from the Electronic Unit Injectors
(2) Water separator (A) Outlet for high pressure fuel to the high (E) Fuel in from the fuel tank
(3) Fuel transfer pump pressure fuel manifold (F) Alternative route for the fuel (air cooled
(4) Fuel cooler (optional) (B) Return from the Pressure Relief Valve ECM)
(5) ECM that is fuel cooled. (PRV) on the high pressure fuel manifold
(6) Secondary fuel filter (C) Return to fuel tank
22 RENR7967
Fuel is drawn from the fuel tank (E) through a 20

micron Primary fuel filter (1) and the Water separator
(2) to the Transfer pump (3). The transfer pump
increases the fuel pressure to 25 kPa (3.6260 psi).
The fuel is pumped through the fuel cooler (optional)
(4) to the ECM (5). The fuel cools the ECM. The fuel
passes from the ECM to a 2 micron fuel filter (6). The
fuel filter removes particulates from 20 microns to 2
microns in size in order to prevent contamination of
the high pressure components in the fuel system.
Fuel passes from the fuel filter to the fuel injection
pump (7). The fuel is pumped at an increased
pressure to the high pressure fuel manifold.
Excess fuel from the high pressure fuel pump returns

to the tank through a non-return valve. There is a
small orifice in the fuel filter base in order to bleed
any air back to the tank.
The leak off fuel from the electronic unit injectors

returns from a connection in the cylinder head to the
pressure side of the transfer pump.
RENR7967 23
High Pressure Fuel System
g01288650
Illustration 22
High pressure fuel system (typical example)
(1) Electronic Unit Injector (4) Fuel Pressure Relief Valve (7) Fuel Injection Pump
(2) High Pressure Fuel Manifold (5) Fuel Transfer Pump
(3) Fuel Pressure Sensor (6) Solenoid for the Fuel Injection Pump
24 RENR7967
The fuel injection pump (7) feeds fuel to the high Fuel Priming Pump
pressure fuel manifold (2). The fuel is at a pressure
of 70 MPa (10152.7 psi) to 130 MPa (18855 psi). A
pressure sensor (3) in the high pressure fuel manifold
(2) monitors the fuel pressure in the high pressure
fuel manifold (2). The ECM controls a solenoid (6) in
the fuel injection pump (7) in order to maintain the
actual pressure in the high pressure fuel manifold
(2) at the desired level. The high pressure fuel is
continuously available at each injector. The ECM
determines the correct time for activation of the
correct electronic unit injector (1) which allows fuel
to be injected into the cylinder. The leakoff fuel from
each injector passes into a drilling which runs along
the inside of the cylinder head. A pipe is connected
to the rear of the cylinder head in order to return the
leakoff fuel to the pressure side of the fuel transfer
pump.
Components of the Fuel Injection System

The fuel injection system has the following
mechanical components: Illustration 23
g01265623
Hand Fuel Priming Pump

• Primary filter/water separator
The pump has a plunger (1) which is manually
• Fuel priming pump operated in order to prime the fuel system. Air is
removed from the fuel system to the fuel return line
• Secondary fuel filter to the tank. The fuel transfer pump is located in the
fuel injection pump. A water drain(2)is installed at the
• Fuel injection pump bottom of the filter in order to remove any water that
has contaminated the fuel.
• Fuel injectors
The electric fuel priming pump can be installed on
• Fuel manifold some engines.
• Pressure relief valve
• Fuel pressure sensor
The following list contains examples of both
service and repairs when you must prime the
system:
• A fuel filter is changed.

• A fuel line is replaced.
• The fuel injection pump is replaced.
Primary Filter/water Separator

The primary filter/water separator is located between
the fuel tank and the priming pump.
RENR7967 25
Secondary Fuel Filter Fuel Injection Pump
g01249050 g01266023
Typical example Typical example
The secondary fuel filter (1) is located after the The fuel injection pump has the following
priming pump. The filter is always before the fuel operations:
injection pump.
• Generation of high pressure fuel
Fuel Pump Assembly The fuel output of the fuel injection pump is controlled
by the ECM in response to changes in fuel pressure.
The fuel pump assembly consists of a low pressure
transfer pump (2) and a high pressure fuel injection
pump (1). The pump assembly is driven from a gear Fuel Transfer Pump
in the front timing case at half engine speed. The fuel
injection pump has two pistons that are driven by a
camshaft. There is a cam for each piston and each
cam has three lobes. The fuel injection pump delivers
a volume of fuel four times for each revolution. The
stroke of the pistons is fixed. The injector will use
only part of the fuel that is delivered by each stroke
of the pistons in the pump. The solenoid for the fuel
injection pump is controlled by the ECM in order to
maintain the fuel manifold pressure at the correct
level. The solenoid allows excess fuel to be diverted
away from the fuel manifold and back to the tank. A
feature of the fuel injection pump allows fuel to return
to the tank continuously.
g01265683
Illustration 26
The fuel transfer pump is a serviceable component.

26 RENR7967
The fuel transfer pump provides a relatively low fuel

pressure to the fuel injection pump. The fuel transfer
pump has a regulating valve in order to control the
low pressure. The fuel transfer pump circulates fuel
through the primary fuel filter and the secondary fuel
filter. The fuel transfer pump has a fuel bypass valve
in order to allow the low pressure fuel system to be
primed.
Shutoff
The engine shuts off by interrupting the fuel supply.
The engine electronic control module (ECM) specifies
the amount of fuel. The quantity of the fuel that is
required by the ECM is set to zero.
Control
g01216984
Illustration 27
Electronic control for the fuel system (typical example)
The ECM determines the quantity, timing and The amount of fuel is proportional to the duration of
pressure of the fuel in order to be injected into the the signal to the injector solenoid.
fuel injector.
The ECM uses input from the sensors on the engine.

These sensors include the speed/timing sensors and
the pressure sensors.
The ECM controls the fuel pressure by increasing

or decreasing the flow of fuel from the fuel injection
pump. The ECM controls the timing and the flow of
fuel by actuating the injector solenoid.
RENR7967 27
Fuel Injectors Fuel Manifold
g01201611
Illustration 28
The fuel injectors are not serviceable.
When the ECM sends a signal to the injector

solenoid, a valve inside the injector opens. The valve
allows the high pressure fuel from the fuel manifold Illustration 29
g01266024
to enter the injector. The pressure of the fuel pushes
Typical example
the needle valve and a spring. When the force of the
fuel pressure is greater than the force of the spring,
The fuel manifold (1) stores high pressure fuel from
the needle valve will lift up.
the fuel injection pump. The high pressure fuel will
flow to the injectors.
The timing and duration of injection is controlled by
a solenoid valve in the injector. The valve has two
The fuel pressure sensor (2) measures the fuel
positions. In the closed position, the valve closes the
pressure in the fuel manifold (1).
inlet to the injector. In this position, fuel above the
injector needle is allowed to vent through the leakoff
The relief valve (3) will prevent the fuel pressure from
port.
getting too high.
In the open position, the valve opens the inlet to the
injector. Simultaneously, the valve closes the leakoff i02531522
port in order to allow high pressure fuel to flow to the
needle. When the solenoid valve is closed, some fuel Electronic Control System
escapes past the valve in order to vent through the
leakoff port. A certain volume of fuel always flows
from the leakoff port. If the volume of fuel increases
Introduction (Electronic Control
beyond a critical level, the high pressure fuel pump System)
will not be able to maintain pressure in the fuel
manifold. The faulty electronic unit injector must be The ECM and the sensors are located on the left side
identified and replaced. of the engine. Refer to illustration 30.
When the signal to the injector ends, the valve closes.

The fuel in the injector changes to a low pressure.
When the pressure drops the needle valve will close
and the injection cycle stops. When the needle valve
opens, fuel under high pressure will flow through
nozzle orifices into the cylinder. The fuel is injected
into the cylinder through the orifices in the nozzle as
a very fine spray.
The needle valve has a close fit with the inside of the
nozzle. This makes a positive seal for the valve.
28 RENR7967
g01248060
Illustration 30
A typical example of a 1104D electronic control system
(1) Fuel Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor
(2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor
(3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
(4) Primary Speed/Timing Sensor (8) Solenoid for the Fuel Injection Pump (11) Coolant Temperature Sensor
Note: If equipped, the wastegate solenoid is installed

on the right side of the engine.
RENR7967 29
g01248066
Illustration 31
30 RENR7967
Table 1
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P532 Fuel Injection Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P228 Fuel Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector (if equipped)
P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P601 Wastegate Valve (if equipped) (2 Pin Connector)
The 1104D engine was designed for electronic

control. The engine has an Electronic Control
Module (ECM), a fuel injection pump and electronic
unit injectors. All of these items are electronically
controlled. There are also a number of engine
sensors. Turbocharged engines can be equipped
with an electronically controlled wastegate for
the turbocharger. The ECM controls the engine
operating parameters through the software within
the ECM and the inputs from the various sensors.
The software contains parameters that control the
engine operation. The parameters include all of the
operating maps and customer selected parameters.
RENR7967 31
g01236714
Illustration 32
The electronic control system has the following

components:
• ECM
• Pressure Sensors
• Temperature Sensors
• Crankshaft Position Sensor
• Secondary Position Sensor
• Solenoid for the Fuel Injection Pump
• Wastegate Solenoid
• Electronic Unit Injectors
32 RENR7967
ECM The personality module contains the software with

all the fuel setting information. The information
determines the engine performance.
Flash programming is the method of programming

or updating the personality module. Refer to the
following Troubleshooting, RENR2417, “Flashing
Programming ” for the instructions on the flash
programming of the personality module.
The ECM is sealed and the ECM needs no routine

adjustment or maintenance.
Engine Speed Governor

The electronic controls determine the injection timing,
the amount of fuel that is delivered to the cylinders
and the intake manifold pressure if an electronically
controlled wastegate is installed on the turbocharger.
These decisions are based on the actual conditions
and the desired conditions at any given time.
g01199973 The governor has software that compares the desired
Illustration 33
Typical example engine speed to the actual engine speed. The actual
engine speed is determined through the primary
The Electronic Control Module (ECM) (1) functions speed/timing sensor and the secondary speed/timing
as a governor and a computer for the fuel system. sensor. If the desired engine speed is greater than
The ECM receives signals from the sensors in order the actual engine speed, the governor injects more
to control the timing and the engine speed. fuel in order to increase engine speed.
The electronic system consists of the ECM, the Timing Considerations

engine sensors and inputs from the parent machine.
The ECM is the computer. The personality module Once the governor has determined the amount of
is the software for the computer. The personality fuel that is required, the software must determine the
module contains the operating maps. The operating timing of the fuel injection. Fuel injection timing is
maps define the following characteristics of the determined by the ECM after considering input from
engine: the following components:
• Engine power • Engine coolant temperature sensor

• Torque curves • The sensor for the intake manifold air temperature
• Engine speed (rpm) • The sensor for the intake manifold pressure
• Engine Noise
• Smoke and Emissions
The factory passwords restrict changes to authorized
personnel. Factory passwords are required to
clear any event code. Refer to the following
Troubleshooting, “Factory Passwords” For more
information on the passwords.
The ECM has an excellent record of reliability. Any

problems in the system are most likely to be the
connectors and the wiring harness. The ECM should
be the last item in troubleshooting the engine.
RENR7967 33
At start-up, the ECM determines the top center If the operator indicates that a performance problem
position of the number 1 cylinder from the secondary has occurred, the diagnostic code may indicate the
speed/timing sensor in the fuel injection pump. cause of the problem. Use a laptop computer to
The ECM decides when fuel injection should occur access the diagnostic codes. The problem should
relative to the top center position. The ECM optimizes then be corrected.
engine performance by control of each of the
electronic unit injectors so that the required amount Event Codes
of fuel is injected at the precise point of the engine’s
cycle. The electronic unit injectors are supplied high Event Codes are used to indicate that the ECM has
pressure fuel from the fuel injection pump. The ECM detected an abnormal engine operating condition.
also provides the signal to the solenoid in the fuel The ECM will log the occurrence of the event code.
injection pump. The solenoid in the fuel injection This does not indicate an electrical malfunction or
pump controls a valve in the fuel injection pump. This an electronic malfunction. If the temperature of the
valve controls the pressure in the fuel injection pump. coolant in the engine is higher than the permitted
Fuel that is not required for the engine is diverted limit, then the ECM will detect the condition. The
away from the fuel injection pump back to the fuel ECM will then log an event code for the condition.
tank.
The ECM adjusts injection timing and fuel pressure Passwords

for the best engine performance, the best fuel
economy and the best control of exhaust emissions. System Configuration Parameters are protected by
The actual timing can be viewed with an electronic factory passwords. This will prevent unauthorized
service tool. Also, the desired timing can be viewed reprogramming of the system and the unauthorized
with an electronic service tool. removal of logged events. Factory passwords are
calculated on a computer system that is available
only to Perkins distributors. Since factory passwords
Fuel Injection contain alphabetic characters, only an electronic
service tool may change System Configuration
The personality module software inside the ECM
Parameters. System Configuration Parameters affect
sets certain limits on the amount of fuel that can be the power rating or the emissions. Passwords also
injected.
allow the customer to control certain programmable
engine parameters.
The FRC Limit is a limit that is based on intake
manifold air pressure and engine rpm. The FRC
Refer to Troubleshooting, “Programming Parameters”
Limit is used to control the air/fuel ratio in order to
and Troubleshooting, “Factory Passwords”.
control the engine’s exhaust emissions. When the
ECM senses a higher intake manifold air pressure,
the ECM increases the FRC Limit. A higher intake Speed/Timing Sensor
manifold air pressure indicates that there is more air
in the cylinder. When the ECM increases the FRC
Limit, the ECM allows more fuel into the cylinder.
The Rated Fuel Limit is a limit that is based on the

power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and
torque outputs to conform to the power and torque
curves of a specific engine model.
These limits are in the personality module and these

limits cannot be changed.
Diagnostic Codes
When the ECM detects an electronic system problem,
the ECM generates a diagnostic code. Also, the ECM
logs the diagnostic code in order to indicate the time
of the problem’s occurrence. The ECM also logs the
number of occurrences of the problem. Diagnostic
codes are provided in order to indicate that the ECM
g01266457
has detected an electrical problem or an electronic Illustration 34
problem with the engine control system. In some Timing wheel on the crankshaft
cases, the engine performance can be affected when
the condition that is causing the code exists.
34 RENR7967
The primary engine position is a passive sensor. The

timing wheel (1) is located on the crankshaft. The
speed/timing sensor receives a signal from the teeth
on timing wheel. The extra space on the timing wheel
gives one revolution per space. The space is oriented
so that the space is 40 degrees after top center.
g01266905
Illustration 35
Schematic for speed/timing sensor
g01266620
Illustration 36
RENR7967 35
When the engine is cranking, the ECM uses the

signal from the speed/timing sensor in the fuel
injection pump. When the engine is running the ECM
uses the signal from the speed/timing sensor on the
crankshaft. This speed/timing sensor is the primary
source of the engine position.
Pressure Sensors
g01266903
Illustration 37
Schematic for pressure sensors
The boost pressure sensor and the engine oil The operating range for the engine oil pressure
pressure sensor are active sensors. sensor ................ 55 kPa to 339 kPa (8 psi to 50 psi)
The boost pressure sensor provides the ECM with a

measurement of inlet manifold pressure in order to
control the air/fuel ratio. This will reduce the engine
smoke during transient conditions.
The operating range of the boost pressure sensors
For standard power engines,

the range is up to the following. .................. 339 kPa
(49.169 psi)
For all high power engine,

the range is up to the following. .................. 440 kPa
(63.818 psi)
The engine oil pressure sensor provides the ECM

with a measurement of engine oil pressure. The ECM
can warn the operator of possible conditions that can
damage the engine. This includes the detection of
an oil filter that is blocked.
36 RENR7967
Temperature Sensors
g01249915
Illustration 38
Schematic for the temperature sensors
The air inlet temperature sensor and the coolant

temperature sensor are passive sensors. Each
sensor provides a temperature input to the ECM. The
ECM controls following operations:
• Fuel delivery
• Injection timing
The operating range for the
sensors ............ í40 °C to 150 °C (í40 °F to 302 °F)
The sensors are also used for engine monitoring.
i02532754
Power Sources
Introduction (Power Supplies)
The 1104D Engine supplies power to the ECM.
The ECM powers the following components:
• All sensors on the engine

• The solenoid for the fuel Injection Pump
• The solenoid for the Wastegate (optional)
• Diagnostic connector
• Electronic unit injectors
The glow plugs are powered directly from the battery.
RENR7967 37
ECM Power Supply
g01245123
Illustration 39
Schematic for ECM
The power supply to the ECM and the system

is drawn from the 24 volt or the 12 volt battery.
The power supply for the ECM has the following
components:
• Battery
• disconnect switch
• Key start switch
• Fuses
• Ground bolt
• ECM connector
• Machine interface connector
The Schematic for the ECM shows the main
components for a typical power supply circuit. Battery
voltage is normally connected to the ECM. The input
from the key start switch turns on the ECM.
The wiring harness can be bypassed for

troubleshooting purposes.
The display screen on the electronic service tool can

be used in order to check the voltage supply.
38 RENR7967
Power Supply for the Pressure

Sensors
g01266903
Illustration 40
Schematic for pressure sensors
The ECM supplies 5.0 ± 0.2 DC volts through the

ECM connector to each sensor. The power supply is
protected against short circuits. A short in a sensor or
a wiring harness will not cause damage to the ECM.
RENR7967 39
Power supply for the Glow plugs
g01245657
Illustration 41
Schematic for the glow plugs
Adaptive Trim – This is a software process that
is performed in the ECM that optimizes engine
i02533811 performance by automatically compensating for
degradation of injector components.
Glossary of Electronic Control
Terms Alternating Current (AC) – Alternating current is an
electric current that reverses direction at a regular
Air-To-Air Aftercooler – An air-to-air aftercooler is a interval that is reoccurring.
device that is used on turbocharged engines in order
to cool inlet air that has undergone compression. The Before Top Center (BTC) – BTC is the 180 degrees
inlet air is cooled after the inlet air passes through of crankshaft rotation before the piston reaches the
the turbocharger. The inlet air is passed through an top center position in the normal direction of rotation.
aftercooler (heat exchanger) that uses ambient air for
cooling. The inlet air that has been cooled advances Breakout Harness – The breakout harness is a
to the inlet manifold. test harness that is designed to connect into the
engine harness. This connection allows a normal
Active Diagnostic Code – An active diagnostic circuit operation and the connection simultaneously
code alerts the operator or the service technician that provides a Breakout T in order to measure the
an electronic system malfunction is currently present. signals.
Refer to the term “Diagnostic Code” in this glossary.
Bypass Circuit – A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit.
40 RENR7967
CAN Data Link (see also J1939 CAN Data Link) – Diagnostic Lamp – A diagnostic lamp is sometimes
The CAN Data Link is a serial communications called the check engine light. The diagnostic lamp
port that is used for communication with other is used to warn the operator of the presence of an
microprocessor based devices. active diagnostic code. The diagnostic lamps are
red and orange. The lamp may not be included in
Code – Refer to “Diagnostic Code” or “Event Code”. all applications.
Cold Mode – Cold mode is a mode for cold starting Digital Sensor Return – The common line (ground)
and for cold engine operation. This mode is used for from the ECM is used as ground for the digital
engine protection, reduced smoke emissions and sensors.
faster warm up time.
Digital Sensors – Digital sensors produce a pulse
Communication Adapter Tool – The width modulated signal. Digital sensors are supplied
communication adapter provides a communication with power from the ECM.
link between the ECM and the Electronic Service
Tool. Digital Sensor Supply – The power supply for the
digital sensors is provided by the ECM.
Component Identifier (CID) – The CID is a number
that identifies the specific component of the electronic Direct Current (DC) – Direct current is the type of
control system that has experienced a diagnostic current that flows consistently in only one direction.
code.
Duty Cycle – See Pulse Width Modulation.
Coolant Temperature Sensor – The coolant
temperature sensor detects the engine coolant DT, DT Connector, or Deutsch DT – This is a type
temperature for all normal operating conditions and of connector that is used on Perkins engines. The
for engine monitoring. connectors are manufactured by Deutsch.
Code – See the Diagnostic Code. Electronic Service Tool – The electronic service
tool is used for diagnosing a variety of electronic
Customer Specified Parameters – A customer controls and the electronic service tool is also used
specified parameter is a parameter that can be for programming a variety of electronic controls.
changed in the ECM with the Electronic Service Tool.
A customer specified parameter’s value is set by Electronic Engine Control – The electronic
the customer. These parameters are protected by engine control is a complete electronic system.
customer passwords. The electronic engine control monitors the engine
operation under all conditions. The electronic engine
Data Link – The Data Link is a serial communication control also controls the engine operation under all
port that is used for communication with other conditions.
microprocessor based devices.
Engine Control Module (ECM) – The ECM is the
Derate – Certain engine conditions will generate control computer of the engine. The ECM provides
event codes. Also, engine derates may be applied. power to the electronics. The ECM monitors data that
The map for the engine derate is programmed into is input from the sensors of the engine. The ECM
the ECM software. The derate can be one or more of acts as a governor in order to control the speed and
3 types: reduction of rated power, reduction of rated the power of the engine.
engine speed, and reduction of rated machine speed
for OEM products. Electronic Service Tool – The electronic service
tool allows a computer (PC) to communicate with the
Desired Engine Speed – The desired engine speed ECM.
is input to the electronic governor within the ECM.
The electronic governor uses the signal from the Engine Monitoring – Engine Monitoring is the part
throttle position sensor, the engine speed/timing of the electronic engine control that monitors the
sensor, and other sensors in order to determine the sensors. This also warns the operator of detected
desired engine speed. problems.
Diagnostic Code – A diagnostic code is sometimes Engine Oil Pressure Sensor – The engine oil
referred to as a fault code. These codes indicate an pressure sensor measures engine oil pressure. The
electronic system malfunction. sensor sends an electronic signal to the ECM that is
dependent on the engine oil pressure.
RENR7967 41
Engine Speed/Timing Sensor – An engine 14 and 15 – These locations are reserved for a
speed/timing sensor is a Hall effect sensor. The future assignment.
ECM interprets this signal as the crankshaft position
and the engine speed. Two sensors are used to Flash Programming – Flash programming is the
provide the speed and timing signals to the ECM. method of programming or updating an ECM with an
The primary sensor is associated with the crankshaft electronic service tool over the data link.
and the secondary sensor is associated with the fuel
injection pump camshaft. Fuel Injector E-Trim – Fuel injector E-trim is a
software process that allows precise control of fuel
Estimated Dynamic Timing – Estimated dynamic injectors by parameters that are programmed into
timing is the estimate of the actual injection timing the ECM for each fuel injector. With the use of the
that is calculated by the ECM. electronic service tool, the service technician can
read status information for the E-Trim. Data for
Ether Relay – The ether relay is used to actuate the E-Trim can also be programmed.
ether injection system. The ECM controls the relay.
Flash Memory – See the Programmable software.
Event Code – An event code may be activated
in order to indicate an abnormal engine operating Fuel Ratio Control (FRC) – The FRC is a limit that
condition. These codes usually indicate a mechanical is based on the control of the fuel to the air ratio. The
problem instead of an electrical system problem. FRC is used for emission control. When the ECM
senses a higher turbocharger outlet pressure, the
Failure Mode Identifier (FMI) – This identifier ECM increases the limit for the FRC in order to allow
indicates the type of failure that is associated with more fuel into the cylinders.
the component. The FMI has been adopted from the
SAE practice of J1587 diagnostics. The FMI follows Fuel Pump – See “Fuel Injection Pump”.
the parameter identifier (PID) in the descriptions of
the fault code. The descriptions of the FMIs are in Fuel Rail – This item is sometimes referred to as
the following list. the High Pressure Fuel Rail or high pressure fuel
manifold. The fuel rail supplies fuel to the electronic
0 – The data is valid but the data is above the normal unit injectors. The fuel injection pump and the fuel
operational range. rail pressure sensor work with the ECM in order to
maintain the desired fuel pressure in the fuel rail. This
1 – The data is valid but the data is below the normal pressure is determined by calibration of the engine
operational range. in order to enable the engine to meet emissions and
performance requirements.
2 – The data is erratic, intermittent, or incorrect.
Fuel Rail Pressure Sensor – The fuel rail pressure
3 – The voltage is above normal or the voltage is sensor sends an electronic signal to the ECM that is
shorted high. dependent on the pressure of the fuel in the fuel rail.
4 – The voltage is below normal or the voltage is Fuel Injection Pump – This item is sometimes
shorted low. referred to as the High Pressure Fuel Rail Pump.
This is a device that supplies fuel under pressure to
5 – The current is below normal or the circuit is open. the fuel rail (high pressure fuel rail).
6 – The current is above normal or the circuit is The Solenoid Valve for the Fuel Injection Pump –
grounded. This is sometimes referred to as the High Pressure
Fuel Rail Pump Solenoid Valve. This is a control
7 – The mechanical system is not responding device in the fuel injection pump. The ECM controls
properly. the pressure in the fuel rail by using this valve to
divert excess fuel from the pump to the fuel tank.
8 – There is an abnormal frequency, an abnormal
pulse width, or an abnormal time period. Full Load Setting (FLS) – The FLS is the number
that represents the fuel system adjustment. This
9 – There has been an abnormal update. adjustment is made at the factory in order to fine tune
the fuel system. The correct value for this parameter
10 – There is an abnormal rate of change. is stamped on the engine information ratings plate.
This parameter must be programmed.
11 – The failure mode is not identifiable.
12 – The device or the component is damaged.
13 – The device or the component is not calibrated.

42 RENR7967
Glow Plug – The glow plug is an optional starting aid Integrated Electronic Controls – The engine is
for cold conditions. One glow plug is installed in each designed with the electronic controls as a necessary
combustion chamber in order to improve the ability of part of the system. The engine will not operate
the engine to start. The ECM uses information from without the electronic controls.
the engine sensors such as the engine temperature
to determine when the glow plug relay must provide Intake Manifold Pressure Sensor – The Intake
power to each glow plug. Each of the glow plugs Manifold Pressure Sensor measures the pressure
then provides a very hot surface in the combustion in the intake manifold. The pressure in the intake
chamber in order to vaporize the mixture of air and manifold may be different to the pressure outside
fuel. This improves ignition during the compression the engine (atmospheric pressure). The difference
stroke of the cylinder. in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
Glow Plug Relay – The glow plug relay is controlled
by the ECM in order to provide high current to the J1939 CAN Data Link – Logged diagnostic codes
glow plugs that are used in the starting aid system. are codes which are stored in the memory. These
codes are meant to be an indicator of possible
Harness – The harness is the bundle of wiring causes for intermittent problems. Refer to the
(loom) that connects all components of the electronic term “Diagnostic Code” in this glossary for more
system. information.
Hertz (Hz) – Hertz is the measure of frequency in Logged Diagnostic Codes – Logged diagnostic
cycles per second. codes are codes which are stored in the memory.
These codes are meant to be an indicator of possible
High Pressure Fuel Rail Pump – See “Fuel Rail causes for intermittent problems. Refer to the
Pump”. term “Diagnostic Code” in this glossary for more
information.
High Pressure Fuel Rail Pump Solenoid Valve –
See “Fuel Rail Pump Solenoid Valve”. Open Circuit – An open circuit is a condition that is
caused by an open switch, or by an electrical wire
High Pressure Fuel Rail – See “Fuel Rail”. or a connection that is broken. When this condition
exists, the signal or the supply voltage can no longer
Injector Codes – The injector codes or injector trim reach the intended destination.
codes are numeric codes or alphanumeric codes
that are etched or stamped on individual electronic OEM – OEM is an abbreviation for the Original
unit injectors. These codes are used to fine tune the Equipment Manufacturer. This is the manufacturer of
fuel delivery. the machine or the vehicle that uses the engine.
Injector Trim Files – Injector trim files are Parameter – A parameter is a value or a limit that
downloaded from a disk to the ECM. The injector trim is programmable. This helps determine specific
files compensate for variances in manufacturing of characteristics or behaviors of the engine.
the electronic unit injector. The serial number for the
electronic unit injector must be obtained in order to Parameter Identifier (PID) – A PID is a numerical
retrieve the correct injector trim file. code that contains two digits or three digits. A
numerical code is assigned to each component. The
Inlet Manifold Air Temperature Sensor – The numerical code identifies data via the data link to the
intake manifold air temperature sensor detects the ECM.
air temperature in the intake manifold. The ECM
monitors the air temperature and other data in the Password – A password is a group of numeric
intake manifold in order to adjust injection timing and characters or a group of alphanumeric characters
other performance functions. that is designed to restrict access to parameters. The
electronic system requires correct passwords in order
Inlet Manifold Pressure (Engines that are to change some parameters (Factory Passwords).
turbocharged) – The difference between the Refer to Troubleshooting, “Factory Passwords” for
turbocharger outlet pressure and atmospheric more information.
pressure is commonly referred to as inlet manifold
pressure. The sensor for the inlet manifold air Personality Module – This module is software
pressure measures the amount of boost. that is inside the ECM. The module contains all the
instructions (software) for the ECM and the module
contains the performance maps for a specific engine.
The personality module may be reprogrammed
through flash programming.
RENR7967 43
Programmable Software – The software is Relay – A relay is an electromechanical switch. A

programmed into the ECM. The software contains flow of electricity in one circuit is used to control the
all the instructions (software) for the ECM and the flow of electricity in another circuit. A small current or
software contains the performance maps for a voltage is applied to a relay in order to switch a much
specific engine. The software may be reprogrammed larger current or voltage.
through flash programming.
Sensor – A sensor is used to detect a change in
Position Sensor – This sensor determines the the pressure, in the temperature, or in mechanical
position of the fuel injection pump camshaft during movement. When any of these changes are detected,
start-up. If the speed/timing sensor fails during engine a sensor converts the change into an electrical signal.
operation, the position sensor is used to provide the
signal. The sensor determines the position of the fuel Short Circuit – A short circuit is a condition that has
injection pump camshaft for injection timing and for an electrical circuit that is inadvertently connected to
engine speed. If the position sensor fails, the engine an undesirable point. An example of a short circuit
will continue to operate but the engine will not start. is a wire which rubs against a vehicle frame and
this rubbing eventually wears off the wire insulation.
Power Cycled – Power cycled happens when power Electrical contact with the frame is made and a short
to the ECM is cycled: ON, OFF, and ON. Power circuit results.
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the Signal – The signal is a voltage or a waveform that
START/RUN position. is used in order to transmit information typically from
a sensor to the ECM.
Primary Speed/Timing Sensor – This sensor
determines the position of the crankshaft during Secondary Speed/Timing Sensor – This sensor
engine operation. If the primary speed/timing determines the position of the camshaft during engine
sensor fails during engine operation, the secondary operation. If the primary speed/timing sensor fails
speed/timing sensor is used to provide the signal. during engine operation, the secondary speed/timing
sensor is used to provide the signal.
Pulse Width Modulation (PWM) – The PWM is a
signal that consists of pulses that are of variable Supply Voltage – The supply voltage is a continuous
width. These pulses occur at fixed intervals. The ratio voltage that is supplied to a component in order to
of “TIME ON” versus total “TIME OFF” can be varied. provide the electrical power that is required for the
This ratio is also referred to as a duty cycle. component to operate. The power may be generated
by the ECM or the power may be battery voltage that
is supplied by the engine wiring.
System Configuration Parameters – System

configuration parameters are parameters that affect
emissions and/or operating characteristics of the
engine.
Tattletale – Certain parameters that affect the

operation of the engine are stored in the ECM.
These parameters can be changed by use of the
electronic service tool. The tattletale logs the number
of changes that have been made to the parameter.
The tattletale is stored in the ECM.
g00284479
Illustration 42 Theft Deterrent – This feature uses a four digit code
in order to prevent the engine from starting. The
Rated Fuel Limit – This is a limit that is based on feature requires a password to be entered.
the power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and “T” Harness – This harness is a test harness that
torque outputs to conform to the power and torque is designed to permit normal circuit operation and
curves of a specific engine model. These limits are the measurement of the voltage simultaneously.
in the personality module and these limits cannot be Typically, the harness is inserted between the two
changed. ends of a connector.
Reference Voltage – Reference voltage is a Throttle Position – The throttle position is the
regulated voltage and a steady voltage that is interpretation by the ECM of the signal from the
supplied by the ECM to a sensor. The reference throttle position sensor or the throttle switch.
voltage is used by the sensor to generate a signal
voltage.
44 RENR7967
Throttle Position Sensor – The throttle position

sensor is an electronic sensor that is usually
connected to an accelerator pedal or a hand lever.
This sensor sends a signal to the ECM that is used
to calculate desired engine speed.
Throttle Switch – The throttle switch sends a signal

to the ECM that is used to calculate desired engine
speed.
Timing Calibration – The timing calibration is the

adjustment of an electrical signal. This adjustment is
made in order to correct the timing error between the
camshaft and the engine speed/timing sensors or
between the crankshaft and the engine speed/timing
sensors.
Top Center Position – The top center position refers

to the crankshaft position when the engine piston
position is at the highest point of travel. The engine
must be turned in the normal direction of rotation in
order to reach this point.
Total Tattletale – The total tattletale is the total

number of changes to all the parameters that are
stored in the ECM.
Wait To Start Lamp – This is a lamp that is included

in the cold starting aid circuit in order to indicate when
the wait to start period has expired. The glow plugs
have not deactivated at this point in time.
Wastegate – This is a device in a turbocharged

engine that controls the maximum boost pressure
that is provided to the inlet manifold.
Wastegate Valve – The wastegate valve regulates

the pressure in the inlet manifold to a value that
is determined by the ECM. The wastegate valve
provides the interface between the ECM and the
mechanical system that regulates inlet manifold
pressure to the desired value that is determined by
the software.
RENR7967 45
Testing and Adjusting i02405571
Section Air in Fuel - Test
Fuel System NOTICE

Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
i02563346 authorised personnel that have the correct train-
ing.
Fuel System - Inspect
Before begining ANY work on the fuel system, re-
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
NOTICE Lines” for safety information.
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by Refer to Testing and Adjusting Manual, “Clean-
authorised personnel that have the correct train- liness of Fuel System Components” for detailed
ing. information on the standards of cleanliness that
must be observed during ALL work on the fuel
Before begining ANY work on the fuel system, re- system.
fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
Lines” for safety information. This procedure checks for air in the fuel system. This
procedure also assists in finding the source of the air.
Refer to Systems Operation, “Cleanliness of Fu-
el System Components” for detailed information 1. Examine the fuel system for leaks. Check the fuel
on the standards of cleanliness that must be ob- level in the fuel tank. Air can enter the fuel system
served during ALL work on the fuel system. on the suction side between the fuel transfer pump
and the fuel tank.
A problem with the components that transport fuel
to the engine can cause low fuel pressure. This can
decrease engine performance.
Work carefully around an engine that is running.
1. Check the fuel level in the fuel tank. Ensure that Engine parts that are hot, or parts that are moving,
the vent in the fuel cap is not filled with dirt. can cause personal injury.
2. Check all fuel lines for fuel leakage. The fuel lines 2. Install a suitable fuel flow tube with a visual
must be free from restrictions and faulty bends. sight gauge in the fuel return to tank line. When
Verify that the fuel return line is not collapsed. possible, install the fuel flow tube in a straight
section of the fuel line that is at least 304.8 mm
3. Install new fuel filters. (12 inches) long. Do not install the fuel flow tube
near the following devices that create turbulence:
4. Cut the old filter open with a suitable filter cutter.
Inspect the filter for excess contamination. • Elbows
Determine the source of the contamination. Make
the necessary repairs. • Relief valves
5. Operate the hand priming pump (if equipped). If • Check valves
excessive resistance is felt, check that there is
fuel in the fuel return line to the tank. Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If there is no fuel
that is present in the fuel flow tube, prime the
fuel system. Refer to Testing and Adjusting, “Fuel
System - Prime” for more information. If the engine
starts, check for air in the fuel at varying engine
speeds. When possible, operate the engine under
the conditions which have been suspect.
46 RENR7967
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not

use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the fuel
lines between the fuel tank and the fuel transfer
pump. Repair any leaks that are found.
5. If the source of the air is not found, disconnect

the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer
pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
i02535648
Finding Top Center Position

for No. 1 Piston
Table 2
g00578151 Required Tools
Illustration 43
(1) A steady stream of small bubbles with a diameter of Part
approximately 1.60 mm (0.063 inch) is an acceptable amount Tool Part Description Qty
Number
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) A 21825576 Crankshaft turning tool 1
are also acceptable if there is two seconds to three seconds
intervals between bubbles. B 27610211 Crankshaft timing pin 1
(3) Excessive air bubbles in the fuel are not acceptable.
C 27610212 Camshaft timing pin 1
3. If excessive air is seen in the fuel flow tube in the D 27610289 Crankshaft turning tool 1
fuel return line, install a second fuel flow tube at
the inlet to the fuel transfer pump. If a second fuel E 27610291 Crankshaft turning tool 1
flow tube is not available, move the fuel flow tube
from the fuel return line and install the fuel flow
tube at the inlet to the fuel transfer pump. Observe
the fuel flow during engine cranking. Look for air
bubbles in the fuel. If the engine starts, check for
air in the fuel at varying engine speeds.
If excessive air is not seen at the inlet to the fuel

transfer pump, the air is entering the system after
the fuel transfer pump. Refer to the Testing and
Adjusting, “Fuel System - Prime”.
If excessive air is seen at the inlet to the fuel

transfer pump, air is entering through the suction
side of the fuel system.
To avoid personal injury, always wear eye and face

protection when using pressurized air.
g01268087
Illustration 44
NOTICE (1) Hole for camshaft pin
To avoid damage, do not use more than 55 kPa (8 psi) (2) Hole for crankshaft pin
to pressurize the fuel tank.
RENR7967 47
1. Remove the valve mechanism cover, the glow

plugs, and the cover for the front housing. Refer to NOTICE
Disassembly and Assembly Manual, “Front Cover Ensure that all adjustments and repairs that are
- Remove and Install”. carried out to the fuel system are performed by
authorised personnel that have the correct train-
Note: The crankshaft timing pin can be inserted with ing.
the crankshaft pulley still on the engine.
Before begining ANY work on the fuel system, re-
2. Use tooling (A) to rotate the crankshaft in the fer to Operation and Maintenance Manual, “Gen-
normal direction of the engine until the inlet eral Hazard Information and High Pressure Fuel
valve of the No. 4 cylinder has just opened and Lines” for safety information.
the exhaust valve of the No. 4 cylinder has not
completely closed. Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
Note: Use the alternative Tooling (D) and Tooling (E) information on the standards of cleanliness that
if the access to the front of the engine is restricted. must be observed during ALL work on the fuel
system.
3. Carefully rotate the crankshaft in the normal
direction of the engine in order to align the hole in
the crankshaft with the hole in the cylinder block This procedure must be done before any of the
(2) and the timing case. Insert Tooling (B) fully into following reasons:
the hole in the crankshaft web.
• Removal of the fuel injection pump
4. Insert Tooling (C) through the hole in the camshaft
gear (1) at the top center position for No. 1 piston. • The bolts that hold the fuel injection pump to the
front housing are loosened.
Note: The camshaft gear can rotate a small amount
when the pin is installed. 1. Set the number one piston at the top center piston
on the compression stroke. Refer to Testing and
5. Remove the timing pins from the camshaft gear Adjusting, “Finding Top Center Position for the No.
and the crankshaft web. 1 Pistion” for the procedure.
2. Carefully remove the fuel injection pump from the

i02536614 front housing. Refer to Disassembly and Assembly
Manual, “Fuel Injection Pump - Remove” for the
Fuel Injection Timing - Check correct procedure.
Table 3
Required Tools
Part
Tool Number Part Description Qty
Fuel Injection Pump
A 27610302 1
Timing Tool
g01200897
Illustration 45
3. To check the fuel injection pump timing, follow

Steps 3.a and 3.b.
48 RENR7967
a. Position Tooling (A) onto the shaft (8) of the i02563386

fuel injection pump. Align the lever of Tooling
(A) with the key slot (7). Engage the lever into Fuel Quality - Test
the key slot.
Note: Refer to Systems Operation, “Cleanliness
b. Insert the locking pin of Tooling (A) into the of Fuel System Components” for detailed
hole (6) in fuel injection pump. information on the standards of cleanliness that
must be observed during ALL work on the fuel
If the locking pin can be inserted into the hole, system.
the fuel injection pump timing is correct.
Ensure that all adjustments and repairs are performed
If the locking pin cannot be inserted into the by authorized personnel that have had the correct
hole, the fuel injection pump timing is not training.
correct.
Use the following procedure to test for problems
Note: There should be no resistance when the regarding fuel quality:
locking pin is inserted.
1. Determine if water and/or contaminants are
4. If the fuel injection pump timing has been lost present in the fuel. Check the water separator (if
follow Steps 5 through 9 in order to reset the fuel equipped). If a water separator is not present,
injection pump timing. proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential
5. If necessary, loosen the locking screw (4) on for overnight condensation.
the fuel injection pump. Slide the spacer (5) into
position (X). Tighten the locking screw (4) to a Note: A water separator can appear to be full of fuel
torque of 9 N·m (80 lb in). This will prevent the when the water separator is actually full of water.
locking screw from tightening against the shaft (8).
2. Determine if contaminants are present in the
The fuel injection pump is now unlocked. fuel. Remove a sample of fuel from the bottom
of the fuel tank. Visually inspect the fuel sample
6. Position Tooling (A) onto the shaft (8) of the fuel for contaminants. The color of the fuel is not
injection pump. Align the lever of Tooling (A) with necessarily an indication of fuel quality. However,
the key slot (7) in the fuel injection pump. Engage fuel that is black, brown, and/or similar to sludge
the lever into the key slot. can be an indication of the growth of bacteria or
oil contamination. In cold temperatures, cloudy
7. Use the lever of Tooling (A) to rotate the shaft (8) fuel indicates that the fuel may not be suitable for
until the pin of Tooling (A) can be engaged into operating conditions.
the hole (6). Engage the pin of Tooling (A) into
the hole. Refer to Operation and Maintenance Manual,
“Fuel Recommendations” for more information.
8. Loosen the locking screw (4) in the fuel injection
pump. Slide the spacer (5) into position (Y). 3. If fuel quality is still suspected as a possible
Tighten the locking screw (4) against the shaft cause to problems regarding engine performance,
of the fuel injection pump to a torque of 9 N·m disconnect the fuel inlet line, and temporarily
(80 lb in). operate the engine from a separate source of
fuel that is known to be good. This will determine
The fuel injection pump is now locked. if the problem is caused by fuel quality. If fuel
quality is determined to be the problem, drain the
9. Remove Tooling (A). fuel system and replace the fuel filters. Engine
performance can be affected by the following
10. Reinstall the fuel injection pump to the front characteristics:
housing. Refer to Disassembly and Assembly
Manual, “Fuel Injection Pump - Install” for the • Cetane number of the fuel
correct procedure.
• Air in the fuel
There are functional tests in order to ensure that
electronic unit injectors operate correctly. Refer to • Other fuel characteristics
Troubleshooting for further information.
RENR7967 49
i02543918
Fuel System - Prime

Refer to the Operation and Maintenance Manual ,

“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
Note: Refer to Systems Operation,Testing

Components” for detailed information on the g01191752
Illustration 46
during ALL work on the fuel system. Typical example
Ensure that all adjustments and repairs are performed 2. Operate the fuel priming pump (1). Count the
by authorized personnel that have had the correct number of operations of the fuel priming pump.
training. After 100 depressions of the fuel priming pump
stop.
NOTICE 3. The engine fuel system should now be primed and
Do not crank the engine continuously for more than the engine should now be able to start.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. Note: Do not loosen the high pressure fuel line
in order to purge air from the fuel system. This
If air enters the fuel system, the air must be purged procedure is not required.
from the fuel system before the engine can be
started. Air can enter the fuel system when the 4. Operate the engine starter and crank the engine.
following events occur: After the engine has started, operate the engine at
low idle for a minimum of five minutes, immediately
• The fuel tank is empty or the fuel tank has been after air has been removed from the fuel system.
partially drained.
Note: Operating the engine for this period of time will
• The low pressure fuel lines are disconnected. help ensure that the fuel system is free of air.
• A leak exists in the low pressure fuel system. After the engine has stopped, you must wait for
60 seconds in order to allow the fuel pressure to
• The fuel filter has been replaced. be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Hand Fuel Priming Pump Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Use the following procedures in order to remove air Replace any high pressure fuel line that has leaked.
from the fuel system: Refer to Disassembly and Assembly, “Fuel Injection
Lines - Install”.
1. Ensure that the fuel system is in working order.
Restore the fuel supply. If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
a fluid penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
50 RENR7967
Electric Fuel Priming Pump i02403273
1. Ensure that the fuel system is in working order. Gear Group (Front) - Time
Restore the fuel supply.
NOTICE
The electric fuel priming pump will operate for 90 sec-
onds. If necessary the electric fuel priming pump can
be stopped during the 90 seconds of operation, by op-
eration of the switch.
2. Turn the keyswitch to the “RUN” position. Operate

the switch for the electric priming pump. After
100 seconds of the electric fuel priming pump
operation the fuel system will be primed and the
electric fuel priming pump will turn off.
3. The engine should now be able to start.

g01194949
Illustration 47
Note: Do not loosen the high pressure fuel line
in order to purge air from the fuel system. This (1) Camshaft gear
(2) Idler gear
procedure is not required. (3) Fuel Injection Pump gear
4. Operate the engine starter and crank the engine. 1. Install the camshaft gear (1) onto the camshaft.
After the engine has started, operate the engine at Refer to Disassembly and Assembly Manual,
low idle for a minimum of five minutes, immediately “Camshaft Gear - Remove and Install” for the
after air has been removed from the fuel system. correct procedure.
Note: Operating the engine for this period of time will 2. Ensure that the crankshaft and the camshaft
help ensure that the fuel system is free of air. are locked in the correct position. Refer to
Disassembly and Assembly Manual, “Gear
After the engine has stopped, you must wait for Group (Front) - Remove and Install” for the
60 seconds in order to allow the fuel pressure to correct procedure. Ensure that the fuel injection
be purged from the high pressure fuel lines before pump is locked in the correct position. Refer
any service or repair is performed on the engine to Disassembly and Assembly Manual, “Fuel
fuel lines. If necessary, perform minor adjustments. Injection Pump - Remove” for the correct
Repair any leaks from the low pressure fuel system procedure.
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked. 3. Install the idler gear (2). Refer to Disassembly
Refer to Disassembly and Assembly Manual, “Fuel and Assembly Manual, “Idler Gear - Remove and
Injection Lines - Install”. Install” for the correct procedure.
If you inspect the engine in operation, always use 4. Install the fuel injection pump gear (3). Refer
the proper inspection procedure in order to avoid to Disassembly and Assembly Manual, “Fuel
a fluid penetration hazard. Refer to Operation and Injection Pump Gear - Install” for the correct
Maintenance Manual, “General hazard Information”. procedure.
5. Make sure that the timing marks on the gears

(1), (2) and (3) are in alignment. If the timing
marks are not aligned, refer to Disassembly and
Assembly Manual, “Gear Group (Front) - Remove
and Install”.
RENR7967 51
Air Inlet and Exhaust

System
i02553540

- Inspect
A general visual inspection should be made to the air
inlet and exhaust system. Make sure that there are
no signs of leaks in the system.
There will be a reduction in the performance of the

engine if there is a restriction in the air inlet system or
the exhaust system.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
g01274757
Illustration 48
Typical unfiltered breather (open circuit)
Making contact with a running engine can cause

burns from hot parts and can cause injury from
rotating parts.
When working on an engine that is running, avoid

contact with hot parts and rotating parts.
1. Inspect the engine air cleaner inlet and ducting

in order to ensure that the passageway is not
blocked or collapsed.
2. Inspect the engine air cleaner element. Replace

a dirty engine air cleaner element with a clean
engine air cleaner element.
3. Check for dirt tracks on the clean side of the

engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the
engine air cleaner element and/or the seal for the
engine air cleaner element.
Note: There are two types of open circuit crankcase

breather that may be installed on the engine, a
filtered breather and an unfiltered breather.
52 RENR7967
5. Remove the breather tube (3) from the breather

(1) and check for obstructions. If the breather
tube is obstructed, use low pressure air to remove
the obstruction. If a filtered breather assembly is
installed, check that the filter element is free from
oil. Ensure that the filter has been renewed at the
correct service interval. Refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule - 500 hours Service” for the correct
procedure. If a blockage is inside the cover (2),
remove the cover. Refer to Disassembly and
Assembly Manual, “Crankcase Breather - Remove
and Install” for the correct procedure. Check the
breather for cracks or external damage. If the
breather is faulty, renew the breather.
Note: The new filter must not be filled with oil when
the canister is renewed.
i02554967
Turbocharger - Inspect
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
NOTICE
g01277997
Illustration 49 Keep all parts clean from contaminants.
Typical filtered breather (Open circuit)
Contaminants may cause rapid wear and shortened
4. If there is excessive crankcase pressure, check component life.
the breather for blockages, and debris. Refer
to Disassembly and Assembly Manual, “Valve
Mechanism Cover - Remove and Install (Filtered NOTICE
Breather) or Remove and Install (Unfiltered Care must be taken to ensure that fluids are contained
Breather)” for the correct procedure. Inspect the during performance of inspection, maintenance, test-
inside of the valve mechanism cover for debris. ing, adjusting and repair of the product. Be prepared to
Ensure that all of the debris is removed. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Note: The breather (1) that is within the valve nent containing fluids.
mechanism cover (2) is not a serviceable item. The
breather should only be renewed if the breather is Dispose of all fluids according to local regulations and
damaged. mandates.
Before you begin inspection of the turbocharger,

be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
exhaust system restriction is within the specifications
for your engine. Refer to Testing and Adjusting, “Air
Inlet and Exhaust System - Inspect”.
RENR7967 53
The condition of the turbocharger will have definite a. Check the oil level in the crankcase. If the oil
effects on engine performance. Use the following level is too high, adjust the oil level.
inspections and procedures to determine the
condition of the turbocharger. b. Inspect the engine crankcase breather. Clean
the engine crankcase breather or replace
• Inspection of the compressor and the compressor the engine crankcase breather if the engine
housing crankcase breather is plugged.
• Inspection of the turbine wheel and the turbine c. Remove the pipe for the oil drain. Inspect the
housing drain opening. Inspect the oil drain line. Inspect
the area between the bearings of the rotating
• Inspection of the wastegate assembly shaft. Look for oil sludge. Inspect the
oil drain hole for oil sludge. Inspect the oil drain
line for oil sludge in the drain line. If necessary,
Inspection of the Compressor and clean the oil drain line.
the Compressor Housing
d. If Steps 3.a through 3.c did not reveal the
source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Turbine Wheel

and the Turbine Housing
Remove the air piping from the turbine housing.
1. Inspect the turbine for damage by a foreign object.

If there is damage, determine the source of the
foreign object. Replace turbocharger (2). If there
is no damage, go to Step 2.
2. Inspect the turbine wheel for the carbon and

other foreign material. Inspect turbine housing
(1) for carbon and foreign material. Replace the
turbocharger, if necessary. If there is no buildup of
carbon or foreign material, go to Step 3.
g01278821 3. Turn the rotating assembly by hand. While you

Illustration 50
turn the assembly, push the assembly sideways.
Typical example of a turbocharger The assembly should turn freely. The turbine
(1) Turbine housing wheel should not rub turbine wheel housing (1).
(2) Compressor housing Replace turbocharger (2) if turbine wheel rubs
turbine housing (1). If there is no rubbing or
1. Inspect the compressor wheel for damage from scraping, go to Step 4.
a foreign object. If there is damage, determine
the source of the foreign object. Replace the 4. Inspect the turbine and turbine housing (1) for oil
turbocharger. If there is no damage, go to Step 2. leakage. Inspect the turbine and turbine housing
(1) for oil coking. Some oil coking may be cleaned.
2. Turn the rotating assembly by hand. While you Heavy oil coking may require replacement of
turn the assembly, push the assembly sideways. the turbocharger. If the oil is coming from the
The assembly should turn freely. The compressor turbocharger center housing go to Step 4.a.
wheel should not rub the compressor housing. The Otherwise go to “Inspection of the Wastegate”.
turbocharger must be replaced if the compressor
wheel rubs the compressor wheel housing. If there a. Remove the pipe for the oil drain. Inspect the
is no rubbing or scraping, go to Step 3. drain opening. Inspect the area between the
bearings of the rotating assembly shaft. Look
3. Inspect the compressor and the compressor for oil sludge. Inspect the oil drain hole for oil
wheel housing for oil leakage. An oil leak from the sludge. Inspect the oil drain line for oil sludge.
compressor may deposit oil in the aftercooler. If oil If necessary, clean the drain line.
is found in the aftercooler, then drain and clean
the aftercooler.
54 RENR7967
b. If crankcase pressure is high, or if the oil drain Check the Wastegate for Proper
is restricted, pressure in the center housing Operation
may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the wrong Table 4
direction and the oil may not drain. Check the
Required Tools
crankcase pressure and correct any problems.
Part
c. If the oil drain line is damaged, replace the oil Tool Number Part Description Qty
drain line. A 21825617 Dial Gauge 1
d. Check the routing of the oil drain line. Eliminate
any sharp restrictive bends. Make sure that
the oil drain line is not too close to the engine
exhaust manifold.
e. If Steps 4.a through 4.d did not reveal the

source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3).
Inspection of the Wastegate

The wastegate controls the amount of exhaust gas
that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the
turbocharger.
When the engine operates in conditions of low

boost (lug), a spring presses against a diaphragm
in the canister. The actuating rod will move and the
wastegate actuator will close. The turbocharger can
then operate at maximum performance.
When the boost pressure increases against the

diaphragm in the canister, the wastegate will open.
The rpm of the turbocharger becomes limited. The
rpm limitation occurs because a portion of the
exhaust gases bypass the turbine wheel of the
turbocharger. Illustration 51
g01289484
Typical example
The following levels of boost pressure indicate a
problem with the wastegate:
Note: The turbocharger is a nonserviceable item.
The pressure for the wastegate can be checked, but
• Too high at full load conditions not adjusted.
• Too low at all lug conditions 1. Disconnect the pipe for the boost sensor (6) at
the wastegate actuator (5). Connect an air supply
The boost pressure controls the maximum rpm of the
to the wastegate actuator that can be adjusted
turbocharger, because the boost pressure controls
accurately.
the position of the wastegate. The following factors
also affect the maximum rpm of the turbocharger:
2. Install Tooling (A) to the turbocharger so that
the end of the actuator rod (1) is in contact with
• The engine rating Tooling (A). This will measure axial movement of
the actuator rod (4).
• The horsepower demand on the engine
• The high idle rpm
• Inlet air restriction
• Exhaust system restriction
RENR7967 55
3. Slowly apply air pressure to the wastegate so that • All glow plugs are removed.
the actuator rod (4) moves 1.0 mm (0.039 inch).
The air pressure should be within 107 to 117 kPa • The fuel supply is disconnected.
(15.5 to 17.0 psi). Ensure that the dial indicator
returns to zero when the air pressure is released.
Repeat the test several times. This will ensure that
an accurate reading is obtained.
4. If the operation of the wastegate is not correct, the

actuator rod (4) can be adjusted.
5. Remove Tooling (A) from the turbocharger.
6. When the air pressure is applied, loosen the nut

on the actuator. Remove the circlip (1). Remove
the pin (2) from the actuator rod (4).
7. When the air pressure is too low, adjust the end of

the actuator rod (4) in order to reduce the length
of the actuator rod (4). If the air pressure is too
high, adjust the end of the actuator rod (4) in order
to increase the length of the actuator rod (4).
8. Install the pin (2) to the actuator rod (4). Install the
circlip (1) to the actuator rod (4). Tighten the nut to g01282556
a torque of 5 N·m (44 lb in). Illustration 52
Typical example
9. Repeat steps 2 to 3 in order to repeat the pressure
test. 1. Remove the glow plug (1) from the hole in the
cylinder head (2). Refer to Disassembly and
10. If the air pressure is correct, remove the air Assembly Manual, “Glowplugs - Remove and
supply. Remove Tooling (A). Install the pipe for the Install” for the correct procedure for the removal of
boost sensor (7). the glow plug (1).
2. Install a suitable gauge for measuring the cylinder

i02562219 compression in the hole for a glow plug.
Compression - Test 3. Operate the starting motor in order to turn the
engine. Record the maximum pressure which is
indicated on the compression gauge.
The cylinder compression test should only be used in 4. Repeat steps 1 to 3 for all cylinders.
order to compare the cylinders of an engine. If one or
more cylinders vary by more than 350 kPa (51 psi),
the cylinder and related components may need to
be repaired.
A compression test should not be the only method

which is used to determine the condition of an engine.
Other tests should also be conducted in order to
determine if the adjustment or the replacement of
components is required.
Before the performance of the compression test,

make sure that the following conditions exist:
• The battery is in good condition.

• The battery is fully charged.
• The starting motor operates correctly.
• The valve lash is set correctly.
56 RENR7967
i02556539 Too much valve lash can cause broken valve stems,
springs, and spring retainers. This will produce
Engine Valve Lash - emissions in excess of the correct specification.
Inspect/Adjust Too much valve lash can be an indication of the
following problems:
Table 5 • Worn camshaft and valve lifters

Required Tools
• Worn rocker arms
Part
Tool Number Part Description Qty • Bent pushrods
A 27610298 Angled feeler gauge 1
• Broken socket on the upper end of a pushrod
• Loose adjustment screw for the valve lash
If the camshaft and valve lifters show rapid wear,
look for fuel in the lubrication oil or dirty lubrication
oil as a possible cause.
Valve Lash Check

An adjustment is NOT NECESSARY if the
measurement of the valve lash is in the acceptable
range. Check the valve lash while the engine is
stopped. The temperature of the engine does not
change the valve lash setting.
If the measurement is not within the acceptable

clearance, adjustment is necessary. Refer to “Valve
Lash Adjustment”.
Valve Lash Adjustment

g01187485
Illustration 53
Table 6
Cylinder and valve location
Inlet Valves Exhaust Valves
(A) Exhaust valve
(B) Inlet valve 0.35 ± 0.05 mm 0.35 ± 0.05 mm
Valve Lash (0.0138 ± 0.0020 (0.0138 ± 0.0020
If the valve lash requires adjustment several times inch) inch)
in a short period of time, excessive wear exists in
a different part of the engine. Find the problem and Firing Order 1-3-4-2(2)
make necessary repairs in order to prevent more (2) The No. 1 Cylinder is at the front of the engine.
damage to the engine.
Note: When the engine is new, the valve lash should
Not enough valve lash can be the cause of rapid be checked and reset after a service interval of 1000
wear of the camshaft and valve lifters. Not enough hours.
valve lash can indicate that the seats for the valves
are worn. Note: For example, if the pushrods in a
remanufactured engine have been replaced with new
Valves become worn due to the following causes: parts then Adjust the valve lash to 0.25 ± 0.05 mm
(0.0098 ± 0.0020 inch) for the initial rebuild.
• Fuel injection nozzles that operate incorrectly The tappets should be reset to 0.35 ± 0.05 mm
(0.0138 ± 0.0020 inch) at the normal service intervals
• Excessive dirt and oil are present on the filters for thereafter.
the inlet air.
• The load capacity of the engine is frequently

exceeded.
RENR7967 57
g01193809
Illustration 54
Setting the valve lash
(A) Angled feeler gauge
(1) Adjustment screw
(2) Locking screw
Accidental engine starting can cause injury or

death to personnel.
To prevent accidental engine starting, turn the ig-

nition switch to the OFF position and place a do
not operate tag at the ignition switch location.
g01278980
Illustration 55
58 RENR7967
1. Remove the valve mechanism cover. Refer to 3. Rotate the crankshaft by 180 degrees in the
Disassembly and Assembly , “Valve Mechanism direction of engine rotation, until the piston of
Cover - Remove and Install” for the removal No. 3 cylinder is at the top center position on the
procedure. compression stroke. The exhaust valves and the
inlet valves of No. 2 cylinder are in valve overlap.
Note: When the valve mechanism cover is removed Adjust the valve lash for both the inlet valves
or installed, the electrical harness must be checked. (5) and the exhaust valves (6) of No. 3 cylinder.
Do not trap the injector harness when the valve Complete the sequence of checks according to
mechanism cover is installed. Do not allow the Table7 until all the cylinders have been checked
harness to be in contact with the valve mechanism or adjusted. Reinstall the valve mechanism cover.
cover. Renew the harness, if the harness is damaged. Refer to Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
Table 7 installation procedure.
Piston in Set valve lash for the following :
top center
i02556543
position
Exhaust valves Inlet valves
and inlet
and exhaust
Valve Depth - Inspect
valves in (Cylinder number) (Cylinder number)
valve overlap
1 2 Table 8
4
(1) (1) Required Tools
5 6 Tool Part Number Part Description Qty

2
(3) (3) A 21825617 Dial gauge 1
7 8 B 21825496 Dial gauge holder 1

1
(4) (4)
3 4
3
(2) (2)
2. See illustration 55. Rotate the crankshaft

clockwise until the piston of No. 1 cylinder is at
the top center position on the compression stroke.
The exhaust valves and the inlet valves of No. 4
cylinder are in valve overlap. Measure the valve
lash on the pair of exhaust valves (1) and the pair
of inlet valves (2) of No. 1 cylinder. If necessary,
adjust the valve lash to the settings in Table 6.
a. See illustration 55. Loosen the valve adjustment

locknut that is on the adjustment screw (1).
b. Place Tooling (A) between the rocker arm

and the valve. Turn the adjustment screw (1)
while the valve adjustment screw locknut (2) is
prevented from turning. Adjust the valve lash Illustration 56
g01201916
until the correct specification is achieved. Typical example
c. After each adjustment, tighten the valve 1. Ensure that the face of the valves are clean.
adjustment screw locknut to 21.5 to 32.5 N·m Ensure that the bottom face of the cylinder head
(15.9 to 24 lb ft) while the valve adjustment is clean. Ensure that the cylinder head is not
screw (1) is held in position. distorted. Refer to Testing and Adjusting, “Cylinder
Head - Inspect” for the procedure to measure
flatness of the cylinder head.
RENR7967 59
2. Use the Tooling (A) to check the depths of the inlet

valves and the exhaust valves below the face of
the cylinder head. Use Tooling (B) to zero Tooling
(A).
3. Measure the depth of the inlet valve and the

exhaust valve below the cylinder head face. The
minimum and maximum limits for a new engine
follow:
Inlet valves
Minimum .................. 0.905 mm (0.0356 inch)
Maximum ................. 1.163 mm (0.0458 inch)
g00314806
Exhaust valves Illustration 57
Measure the radial movement of the valve in the valve guide.
Minimum .................. 0.876 mm (0.0345 inch)
(1) Valve guide
Maximum ................. 1.131 mm (0.0445 inch) (2) Radial movement of the valve in the valve guide
(3) Valve stem
4. Service wear occurs on an engine which has (4) Dial indicator
been in operation. If the valve depth below the (5) Valve head
cylinder head face on a used engine exceeds
the specification for service wear, the following 1. Place a new valve in the valve guide.
components must be replaced.
2. Place a dial indicator with a magnetic base on the
• Valves face of the cylinder head.
• Valve inserts 3. Lift the edge of the valve head to a distance of

15.0 mm (0.60 inch).
Wear limit for inlet valves .. 1.41 mm (0.0555 inch)
4. Move the valve in a radial direction away from the
Wear limit for exhaust valves ................. 1.38 mm dial indicator. Make sure that the valve moves
(0.0543 inch) away from the dial indicator as far as possible.
Position the contact point of the dial indicator on
5. Check each valve for cracks. Check the stems of the edge of the valve head. Set the position of the
the valves for wear. Ensure that the valves are needle of the dial indicator to zero.
the correct fit in the valve guides. Refer to Testing
and Adjusting, “Valve Guide - Inspect” for the 5. Move the valve in a radial direction toward the dial
procedure to inspect the valve guides. indicator as far as possible. Note the distance of
movement which is indicated on the dial indicator.
6. Check the load on the valve springs. Refer to If the distance is greater than the maximum
Specifications, “Cylinder Head Valves” for the clearance of the valve in the valve guide, replace
correct lengths and specifications for the valve the valve guide.
springs.
The maximum clearance for the inlet valve stem
in the valve guide with a valve lift of 15.0 mm
i02400035 (0.60 inch) is the following value. ........... 0.08 mm
(0.0031 inch)
Valve Guide - Inspect
The maximum clearance for the exhaust valve
Perform this test in order to determine if a valve guide stem in the valve guide with a valve lift of 15.0 mm
should be replaced. (0.60 inch) is the following value. ........... 0.09 mm
(0.0035 inch)
60 RENR7967
The original valve guides are bored into the cylinder

head. When new valve guides(1) are installed, new
valves and new valve seat inserts must be installed.
The cylinder head must be rebored in order to install
the new valve guide. Valve guides and valve seat
inserts are supplied as an unfinished part. The
unfinished valve guides and unfinished valve seat
inserts are installed in the cylinder head. Then, the
valve guides and valve inserts are cut and reamed in
one operation with special tooling.
Refer to Disassembly and Assembly, “Inlet and

Exhaust Valve Guides - Remove and install” for the
replacement of the valve guides.
RENR7967 61
Lubrication System Perform the following procedures in order to inspect

the oil pump for clearances and torques.
i02557748
Refer to the Specifications Module, “Engine Oil
Engine Oil Pressure - Test Pump”.
1. Remove the oil pump from the engine. Refer to

the Disassembly and Assembly, “Engine Oil Pump
- Remove”. Remove the cover of the oil pump.
Low Oil Pressure
2. Remove the outer rotor. Clean all of the parts.
The following conditions will cause low oil pressure. Look for cracks in the metal or other damage.
• The oil level is low in the crankcase.

• A restriction exists on the oil suction screen.
• Connections in the oil lines are leaking.
• The connecting rod or the main bearings are worn.
• The rotors in the oil pump are worn.
• The oil pressure relief valve is operating incorrectly.
A worn oil pressure relief valve can allow oil to leak
through the valve which lowers the oil pressure.
Refer to the Specifications Module, “Engine Oil Relief
Valve” for the correct operating pressure and other
information.
When the engine runs at the normal temperature for

operation and at high idle, the oil pressure must be
a minimum of 280 kPa (40 psi). A lower pressure is g00985779
Illustration 58
normal at low idle.
Clearance for the outer rotor body
A suitable pressure gauge can be used in order to (1) Measure the clearance of the outer rotor to the body.
test the pressure of the lubrication system.
3. Install the outer rotor. Measure the clearance of
the outer rotor to the body (1).
High Oil Pressure
High oil pressure can be caused by the following
conditions.
• The spring for the oil pressure relief valve is

installed incorrectly.
• The plunger for the oil pressure relief valve

becomes jammed in the closed position.
• Excessive sludge exists in the oil which makes the

viscosity of the oil too high.
i01893791
Engine Oil Pump - Inspect
If any part of the oil pump is worn enough in order to

affect the performance of the oil pump, the oil pump
must be replaced.
62 RENR7967
i01126690
Excessive Bearing Wear -

Inspect
When some components of the engine show bearing
wear in a short time, the cause can be a restriction in
an oil passage.
An engine oil pressure indicator may show that there

is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component.
A restriction in an oil supply passage will not allow
enough lubrication to reach a component. This will
result in early wear.
i02414692
Excessive Engine Oil

Illustration 59
g00985780
Consumption - Inspect
Clearance for the inner rotor
(2) Measure the clearance of the inner rotor to the outer rotor.
Engine Oil Leaks on the Outside of
4. Measure the clearance of the inner rotor to the the Engine
outer rotor (2).
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the gasket for the
engine oil pan and all lubrication system connections.
Look for any engine oil that may be leaking from
the crankcase breather. This can be caused by
combustion gas leakage around the pistons. A dirty
crankcase breather will cause high pressure in the
crankcase. A dirty crankcase breather will cause the
gaskets and the seals to leak.
Engine Oil Leaks into the

Combustion Area of the Cylinders
Engine oil that is leaking into the combustion area of
the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
the combustion area of the cylinders:
• Failed valve stem seals
g00989217 • Leaks between worn valve guides and valve stems

Illustration 60
• Worn components or damaged components
5. Measure the end play of the rotor with a straight (pistons, piston rings, or dirty return holes for the
edge and a feeler gauge (3). engine oil)
6. Clean the top face of the oil pump and the bottom • Incorrect installation of the compression ring and/or
face of the cover. Install the cover on the oil the intermediate ring
pump. Install the oil pump on the engine. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Install”.
RENR7967 63
• Leaks past the seal rings in the turbocharger shaft

• Overfilling of the crankcase
• Wrong dipstick or guide tube
• Sustained operation at light loads
Excessive consumption of engine oil can also
result if engine oil with the wrong viscosity is used.
Engine oil with a thin viscosity can be caused by fuel
leakage into the crankcase or by increased engine
temperature.
i01945015
Increased Engine Oil

Temperature - Inspect
Look for a restriction in the oil passages of the oil
cooler (if equipped). The oil temperature may be
higher than normal when the engine is operating. In
such a case, the oil cooler may have a restriction.
A restriction in the oil cooler will not cause low oil
pressure in the engine.
64 RENR7967
b. Clean the radiator and other components with
hot water or steam at low pressure. Detergent
Cooling System in the water may also be used. Compressed
air may be used to remove materials from
the cooling system. Identify the cause of the
i02419296 restriction before you choose the method for
cleaning.
Cooling System - Check
c. Straighten any fins of the radiator if the fins
Engine And Cooling System Heat are bent.
Problems 5. Check the high idle of the engine. The engine may
overheat if the high idle rpm is set too high.
1. The following conditions indicate that a heat
problem exists.
i01889427
a. Hot coolant is released through the pressure
cap during the normal operation of the engine. Cooling System - Inspect
Hot coolant can also be released when the
engine is stopped. This engine has a pressure type cooling system. A
pressure type cooling system gives two advantages:
b. Hot coolant is released from the coolant system
but not through the pressure cap during normal • The pressure type cooling system can operate
operation of the engine. Hot coolant can also safely at a higher temperature than the boiling
be released when the engine is stopped. point of water at a range of atmospheric pressures.
c. Coolant must be added frequently to the • The pressure type cooling system prevents
cooling system. The coolant is not released cavitation in the water pump.
through the pressure cap or through an outside
leak. Cavitation is the sudden generation of low pressure
bubbles in liquids by mechanical forces. The
2. If any of the conditions in Step 1 exist, perform generation of an air or steam pocket is much more
the following procedures: difficult in a pressure type cooling system.
a. Run the engine at medium idle, which is Regular inspections of the cooling system should be
approximately 1200 rpm, for three minutes made in order to identify problems before damage
after the high idle shuts off. Running the engine can occur. Visually inspect the cooling system before
at medium idle will allow the engine to cool tests are made with the test equipment.
before the engine is stopped.
Visual Inspection Of The Cooling
b. Inspect the poly v-belt for wear or for damage.
If necessary, replace the poly v-belt. Refer to System
Disassembly and Assembly Manual, “Alternator
Belt - Remove and Install” for the correct 1. Check the coolant level in the cooling system.
procedure.
2. Look for leaks in the system.
3. Refer to “Visual Inspection Of The Cooling
System” in order to determine if a leak exists in 3. Inspect the radiator for bent fins and other
the cooling system. restriction to the flow of air through the radiator.
a. Refer to “Testing The Radiator And Cooling 4. Inspect the drive belt for the fan.
System For Leaks” procedures.
5. Inspect the blades of the fan for damage.
4. If the coolant does not flow through the radiator
and through other components of the cooling 6. Look for air or combustion gas in the cooling
system, perform the following procedures. system.
a. Perform the “Testing The Water Temperature 7. Inspect the radiator cap for damage. The sealing
Regulator ” procedures. surface must be clean.
RENR7967 65
8. Look for large amounts of dirt in the radiator core. The level of the coolant should not be more than
Look for large amounts of dirt on the engine. 13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass,
9. Shrouds that are loose or missing cause poor air the coolant should be to the correct level in the sight
flow for cooling. glass.
i01964006 Checking the Filler Cap

Cooling System - Test One cause for a pressure loss in the cooling system
can be a faulty seal on the radiator pressure cap.
Remember that temperature and pressure work

together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
be checked. The cooling system pressure will have
an effect on the cooling system temperature. For
an example, refer to Illustration 61. This will show
the effect of pressure on the boiling point (steam) of
water. This will also show the effect of height above
sea level.
g00296067
Illustration 62
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator
Personal injury can result from hot coolant, steam

and alkali.
g00286266
At operating temperature, engine coolant is hot
Illustration 61 and under pressure. The radiator and all lines
Cooling system pressure at specific altitudes and boiling points to heaters or the engine contain hot coolant or
of water steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
Personal injury can result from hot coolant, steam enough to touch with your bare hand.
and alkali.
To check for the amount of pressure that opens the
At operating temperature, engine coolant is hot filler cap, use the following procedure:
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or 1. After the engine cools, carefully loosen the filler
steam. Any contact can cause severe burns. cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap.
when engine is stopped and radiator cap is cool 2. Inspect the pressure cap carefully. Look for
enough to touch with your bare hand. damage to the seal. Look for damage to the
surface that seals. Remove any debris on the cap,
The coolant level must be to the correct level in order the seal, or the sealing surface.
to check the coolant system. The engine must be
cold and the engine must not be running. Carefully inspect the filler cap. Look for any
damage to the seals and to the sealing surface.
After the engine is cool, loosen the pressure cap Inspect the following components for any foreign
in order to relieve the pressure out of the cooling substances:
system. Then remove the pressure cap.
• Filler cap
66 RENR7967
• Seal • You do NOT observe any leakage after five

minutes.
• Surface for seal
• The dial indicator remains constant beyond five
Remove any deposits that are found on these minutes.
items, and remove any material that is found on
these items. The inside of the cooling system has leakage only
if the following conditions exist:
3. Install the pressure cap onto a suitable
pressurizing Pump. • The reading on the gauge goes down.
4. Observe the exact pressure that opens the filler • You do NOT observe any outside leakage.
cap.
Make any repairs, as required.
5. Compare the pressure to the pressure rating that
is found on the top of the filler cap.
i02558841
6. If the filler cap is damaged, replace the filler cap. Engine Oil Cooler - Inspect
Testing The Radiator And Cooling
System For Leaks
Use the following procedure to test the radiator and
the cooling system for leaks. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Personal injury can result from hot coolant, steam There is only one type of engine oil cooler that can
and alkali. be installed on this engine.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
1. When the engine has cooled, loosen the filler cap

to the first stop. Allow the pressure to release from
the cooling system. Then remove the filler cap.
2. Make sure that the coolant covers the top of the

radiator core.
3. Put a suitable pressurizing Pump onto the radiator.
4. Use the pressurizing pump to increase the

pressure to an amount of 20 kPa (3 psi) more than
the operating pressure of the filler cap.
5. Check the radiator for leakage on the outside.
6. Check all connections and hoses of the cooling

system for leaks.
The radiator and the cooling system do not have

leakage if all of the following conditions exist:
RENR7967 67
Mounted Filter Dry the oil cooler (1) with low pressure air. Flush
the inside of the oil cooler (1) with clean lubricating
oil.
5. Refer to Disassembly and Assembly , “Engine

Oil Cooler - Install” for installation of the engine
oil cooler.
6. Ensure that the cooling system of the engine is

filled to the correct level. Operate the engine.
Note: Refer to the Operation And Maintenance

Manual, “Refill Capacities” for additional information.
Check for oil or coolant leakage.
i02414647
Water Temperature Regulator

- Test
g01254472
Illustration 63
Typical example
(1) Oil cooler
(2) Joint
(3) Cooler matrix Personal injury can result from escaping fluid un-
(4) Joints der pressure.
(5) Housing
(6) Four setscrews
(7) Setscrews (different lengths) If a pressure indication is shown on the indicator,
push the release valve in order to relieve pressure
Perform the following procedure in order to inspect before removing any hose from the radiator.
the engine oil cooler:
1. Remove the water temperature regulator from
1. Place a container under the oil cooler in order to the engine. Refer to Disassembly and Assembly
collect any engine oil or coolant that drains from Manual, “Water Temperature Regulator - Remove
the oil cooler. and Install”.
2. Refer to Disassembly and Assembly , “Engine 2. Heat water in a pan until the temperature of
Oil Cooler - Remove” for removal of the engine the water is equal to the fully open temperature
oil cooler. of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
3. Thoroughly clean the oil cooler (1) and the cylinder for the fully open temperature of the water
block. temperature regulator. Stir the water in the pan.
This will distribute the temperature throughout the
pan.
Personal injury can result from air pressure. 3. Hang the water temperature regulator in the pan
of water. The water temperature regulator must
Personal injury can result without following prop- be below the surface of the water. The water
er procedure. When using pressure air, wear a pro- temperature regulator must be away from the
tective face shield and protective clothing. sides and the bottom of the pan.
Maximum air pressure at the nozzle must be less 4. Keep the water at the correct temperature for ten
than 205 kPa (30 psi) for cleaning purposes. minutes.
4. Inspect the oil cooler (1) for cracks and dents.

Replace the oil cooler (1) if cracks or dents
exist. Ensure that no restrictions for the flow of
lubricating oil exist in the oil cooler (1).
68 RENR7967
5. After ten minutes, remove the water temperature

regulator. Immediately measure the opening
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
for the minimum opening distance of the
water temperature regulator at the fully open
temperature.
If the distance is less than the amount listed in the

manual, replace the water temperature regulator.
i01628133
Water Pump - Inspect

1. Inspect the water pump for leaks at vent hole. The
water pump seal is lubricated by coolant in the
cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and
the parts contract.
2. Refer to Disassembly and Assembly, “Water Pump

- Remove ” and Disassembly and Assembly,
“Water Pump - Install”.
3. Inspect the water pump shaft for unusual noise,

excessive looseness and/or vibration of the
bearings.
RENR7967 69
Basic Engine Inspect the Piston Ring End Gap
i01889476
Piston Ring Groove - Inspect
Inspect the Piston and the Piston

Rings
1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in the

grooves and that the rings are not broken.
Inspect the Clearance of the Piston

Ring
1. Remove the piston rings and clean the grooves
g00983549
and the piston rings. Illustration 65
(1) Piston ring
(2) Cylinder ring ridge
(3) Feeler gauge
1. Clean all carbon from the top of the cylinder bores.
2. Place each piston ring (1) in the cylinder bore just

below the cylinder ring ridge (2).
3. Use a suitable feeler gauge (3) to measure the

piston ring end gap. Refer to Specifications,
“Piston and Rings” for the dimensions.
Note: The coil spring must be removed from the oil

control ring before the gap of the oil control ring is
measured.
i02560333
Connecting Rod - Inspect

g00905732 These procedures determine the following
Illustration 64
(1) Feeler gauge characteristics of the connecting rod:
(2) Piston ring
(3) Piston grooves • The length of the connecting rod
2. Fit new piston rings (2) in the piston grooves (3). • The distortion of the connecting rod
3. Check the clearance for the piston ring by placing • The parallel alignment of the bores of the
a suitable feeler gauge (1) between the piston connecting rod
groove (3) and the top of piston ring (2). Refer
to Specifications, “Piston and Rings” for the Note: If the crankshaft or the cylinder block are
dimensions. replaced, the piston height for all cylinders must be
measured. The grade of length of the connecting
Note: Some pistons have a tapered top groove and rods may need to be changed in order to obtain the
the piston ring is wedged. The clearance for the top correct piston height.
piston ring cannot be checked by the above method
when this occurs.
70 RENR7967
If the grade of length must be changed, one of the If the piston pin bearing requires replacement but the
following actions must be taken: original connecting rod is not replaced, the following
procedures must be performed:
• New connecting rod assemblies that are the
correct grade of length must be installed. Refer to 1. Determine the grade of length of the connecting
“Length Of The Connecting Rod”. rod. Use one of the following characteristics:
• New piston pin bearings must be bored after • The mark

installation in the original connecting rods. Refer
to “Piston Pin Bearings”. • The color
Note: When the piston pin is installed, always install • Measuring the length
new retaining rings on each end of the piston pin. If
the piston pin cannot be removed by hand, heat the 2. Ensure that the connecting rod is aligned parallel
piston to a temperature of 45° ± 5 °C (113° ± 9 °F) in and that the connecting rod is not distorted. Refer
order to aid the removal of the piston pin. Heating to “Distortion Of A Connecting Rod” in this service
the piston to this temperature may also aid the module.
installation of the piston pin.
3. Remove the piston pin bearing from the connecting
Length of The Connecting Rod rod. Install a new bearing in the connecting rod.
The new bearing is partially finished. The new
bearing must be bored off-center to the correct
The connecting rod length (CRL) is the length of the
connecting rod. Refer to Table 9 for each grade of diameter. This off-center position is determined by
the grade of length of the connecting rod. Refer to
length of connecting rod.
Table 9. The correct diameter of the bore in the
In order to ensure that the piston height above the piston pin bearing is given in the Specifications
Module, “Connecting Rod”.
cylinder block is correct, three grades of connecting
rods “F” to “L” are used during manufacture at the
factory. Replacement connecting rods are available Surface finish of the bored hole in the piston pin
bearing .................................. Ra 0.8 micrometers
in six grades. These grades of connecting rod are
“F” to “L”. The grade of length is identified by a
letter or a color which is marked on the side of the 4. Machine the ends of the piston pin bearing to the
correct length. Remove any sharp edges. Refer to
connecting rod. The longest grade is marked with the
the Specifications Module, “Connecting Rod”.
letter “F”. The shortest grade is marked with the letter
“L”. The difference in length between each grade of
5. If the grade of length of the connecting rod
connecting rods is the following value: 0.046 mm
is changed, the letter that is stamped on the
(0.0018 inch)
connecting rod must be removed. Etch a letter
that is for the new grade of length on the side of
The grade of length of a connecting rod is determined
the connecting rod.
in the factory by machining an eccentric hole in a
semi-finished piston pin bushing. Therefore, the
Note: Do not stamp a new letter on the connecting
grade of length is determined by the position of the
rod. The force of stamping may damage the
center of the hole in the piston pin bearing.
connecting rod.
If the connecting rod must be replaced, a new
Table 9 references the following information: Grade
connecting rod assembly must be purchased and
installed. Refer to Table 9 for more information. of letter of the connecting rod, the color code of the
connecting rods, and the lengths of the connecting
rods.
A new piston pin bearing is installed in the new
connecting rod at the factory. The bore of the piston
pin bearing is reamed to the correct eccentricity.
Piston Pin Bearings

Note: This procedure requires personnel with the
correct training and the use of specialized equipment
for machining.
RENR7967 71
Table 9 Measure “CRL”. Compare the “CRL” that is given

Length Grades for Connecting Rods
in Table 9. The grade of length of the connecting
rod is determined by the “CRL”. Refer to Table 9
Length Of The for the correct grade of length.
Grade Letter Color Code
Connecting Rod (CRL)
F Red
165.728 to 165.761 mm Distortion of The Connecting Rod
(6.5247 to 6.5260 inch)
165.682 to 165.715 mm 1. Use the following tools in order to measure the
G Orange distances for the connecting rod (2) which are
(6.5229 to 6.5242 inch)
specified in Illustration 66:
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
• Appropriate gauges for measuring distance
165.591 to 165.624 mm
J Green
(6.5193 to 6.5206 inch) • Measuring pins (1)
165.545 to 165.578 mm
K Purple
(6.5175 to 6.5188 inch)
165.499 to 165.532 mm
L Blue
(6.5157 to 6.5170 inch)
Measure The Length Of The Connecting

Rod
If the mark or the color of the grade of length cannot
be observed on the connecting rod, perform the
following procedure:
g00326423
Illustration 67
Measure the connecting rod for distortion.
(1) Measuring pins
(2) Connecting rod
(L) The length between the centers of the piston pin bearing and
the crankshaft journal bearing is shown in Illustration 67.
2. Refer to illustration 67. Measure the connecting

rod for distortion and parallel alignment between
the bores.
The bores for the crankshaft bearing and the

bearing for the piston pin must be square and
g00326546 parallel with each other within the required limits.
Illustration 66
Measure the length of the connecting rod. If the piston pin bearing is removed, the limit “L” is
(1) Measuring pins
the following value: ± 0.25 mm (± 0.010 inch)
(2) Connecting rod
(CRL) Connecting Rod Length The limits are measured at a distance of 127 mm
(5.0 inch) from each side of the connecting rod.
1. Refer to Illustration 66. Use the following tools in
order to measure the length of the connecting rod: If the piston pin bearing is not removed, the limit “L”
is the following value: ± 0.06 mm (± 0.0024 inch)
• Appropriate gauges for measuring distance
L is equal to 219.08 ± 0.03 mm (8.625 ± 0.001 inch).
• Measuring pins (1)
3. Inspect the piston pin bearing and the piston pin
2. Ensure that the measuring pins (1) are parallel. for wear.
“CRL” is measured when the bearing for the
crankshaft journal is removed and the original 4. Measure the clearance of the piston pin in the
piston pin bearing is installed. piston pin bearing. Refer to the Specifications
Module, “Connecting Rod” for dimensions.
72 RENR7967
i02399735
Cylinder Block - Inspect

1. Clean all of the coolant passages and the oil
passages.
2. Check the cylinder block for cracks and damage.
3. The top deck of the cylinder block must not be

machined. This will affect the depth of the cylinder
liner flange and the piston height above the
cylinder block.
4. Check the front camshaft bearing for wear. Refer

to Specifications, “Camshaft Bearings” for the
correct specification of the camshaft bearing. If a
new bearing is needed, use a suitable adapter to
press the bearing out of the bore. Ensure that the
oil hole in the new bearing faces the front of the
block. The oil hole in the bearing must be aligned
with the oil hole in the cylinder block. The bearing Illustration 68
g01254471
must be aligned with the face of the recess.
Flatness of the cylinder head (typical example)
(A) Side to side
i02560426 (B) End to end
(C) Diagonal
Cylinder Head - Inspect
8. Measure the cylinder head for flatness. Use a
1. Remove the cylinder head from the engine. straight edge and a feeler gauge to check the
cylinder head for flatness.
2. Remove the water temperature regulator housing.
• Measure the cylinder head from one side to the
3. Inspect the cylinder head for signs of gas or opposite side (A).
coolant leakage.
• Measure the cylinder head from one end to the
4. Remove the valve springs and valves. opposite end (B).
5. Clean the bottom face of the cylinder head • Measure the cylinder head from one corner to
thoroughly. Clean the coolant passages and the opposite corner (C).
the lubricating oil passages. Make sure that the
contact surfaces of the cylinder head and the Refer to Specifications, “Cylinder Head” for the
cylinder block are clean, smooth and flat. requirements of flatness.
6. Inspect the bottom face of the cylinder head for i01889496

pitting, corrosion, and cracks. Inspect the area
around the valve seat inserts and the holes for the Piston Height - Inspect
fuel injection nozzles carefully.
Table 10
7. Test the cylinder head for leaks at a pressure of
200 kPa (29 psi).
Required Tools
Part Part Description Qty

Number
21825617 Dial gauge 1
21825496 Dial gauge holder 1
RENR7967 73
If the height of the piston above the cylinder block 2. Rotate the crankshaft until the piston is at the
is not within the tolerance that is given in the approximate top center.
Specifications Module, “Piston and Rings”, the
bearing for the piston pin must be checked. Refer to 3. Position the dial gauge holder (2) and the dial
Testing and Adjusting, “Connecting Rod - Inspect”. gauge (1) in order to measure the piston height
If any of the following components are replaced or above the cylinder block. Slowly rotate the
remachined, the piston height above the cylinder crankshaft in order to determine when the piston
block must be measured: is at the highest position. Record this dimension.
Compare this dimension with the dimensions that
• Crankshaft are given in Specifications, “Piston and Rings”.
• Cylinder head
i02543991
• Connecting rod Flywheel - Inspect

• Bearing for the piston pin
The correct piston height must be maintained in order Table 11
to ensure that the engine conforms to the standards
for emissions. Required Tools
Part
Note: The top of the piston should not be machined. Tool Number Part Description Qty
If the original piston is installed, be sure that the
A 21825617 Dial Indicator Group 1
original piston is assembled to the correct connecting
rod and installed in the original cylinder.
Six grades of length of connecting rods determine

Alignment of the Flywheel Face
the piston height above the cylinder block. The grade
of length of a connecting rod is identified by a letter or
a color. The letter or the color is marked on the side
of the connecting rod. Refer to Testing and Adjusting,
“Connecting Rod - Inspect” and Specifications,
“Connecting Rod” for additional information.
g01273119
Illustration 70
Typical example
1. Install Tooling (A) in illustration 70, as shown.
2. Set the pointer of the dial indicator to 0 mm

Illustration 69
g00983585 (0 inch).
(1) Dial gauge
(2) Dial gauge holder 3. Turn the flywheel. Read the dial indicator for every
45 degrees.
1. Use the dial gauge (1) and the dial gauge holder
(2) in order to measure the piston height above Note: During the check, keep the crankshaft pressed
the cylinder block. Use the cylinder block face to toward the front of the engine in order to remove any
zero the dial gauge (1). end clearance.
74 RENR7967
4. Calculate the difference between the lowest Concentricity of the Flywheel

measurement and the highest measurement of the
four locations. This difference must not be greater
Housing
than 0.03 mm (0.001 inch) for every 25 mm
Note: This check must be made with the flywheel
(1.0 inch) of the radius of the flywheel. The radius
and the starter removed and the bolts for the flywheel
of the flywheel is measured from the axis of the
housing tightened lightly.
crankshaft to the contact point of the dial indicator.
Flywheel Runout
g01199468
Illustration 72
Typical example
g01273120
Illustration 71 1. Install Tooling (A). See illustration 72.
Typical example
2. Set the pointer of the dial indicator to 0 mm
1. Install Tooling (A) in illustration 71, as shown. (0 inch).
2. Set the pointer of the dial indicator to 0 mm 3. Check the concentricity at intervals of 45 degrees
(0 inch). around the flywheel housing.
3. Turn the flywheel. Read the dial indicator for every 4. Calculate the difference between the lowest
45 degrees. measurement and the highest measurement. This
difference must not be greater than the limit that is
4. Calculate the difference between the lowest given in Table 13.
measurement and the highest measurement of
the four locations. This difference must not be Note: Any necessary adjustment must be made on
greater than 0.30 mm (0.012 inch). the flywheel housing. Then, recheck the concentricity.
i02544044 Alignment of the Flywheel Housing

Flywheel Housing - Inspect Note: This check must be made with the flywheel
and the starter removed and the bolts for the flywheel
housing tightened to the correct torque.
Table 12
Required Tools
Part
Tool Number Part Description Qty
A 21825617 Dial Gauge 1
RENR7967 75
i02543954
Gear Group - Inspect
g01273087
Illustration 74
g01199467 (1) Camshaft gear

Illustration 73 (2) Idler gear
Typical example (3) Fuel injection pump gear
1. Install Tooling (A). See illustration 73. Note: If one or more of the gears need to be removed
for repair, refer to Disassembly and Assembly, “Gear
2. Set the pointer of the dial indicator to 0 mm Group (Front) - Remove and Install” in order to
(0 inch). properly remove the gears. Refer to Disassembly and
Assembly, “Gear Group (Front) - Remove and Install”
3. Check the alignment at intervals of 45 degrees in order to properly install the gears.
around the flywheel housing.
1. Inspect the gears for wear or for damage. If the
4. Calculate the difference between the lowest gears are worn or damaged, use new parts for
measurement and the highest measurement. This replacement.
difference must not be greater than the limit that is
given in Table 13. 2. Measure the backlash between the camshaft
gear (1) and the idler gear (2). Refer to
Note: Any necessary adjustment must be made on Specifications, “Gear Group (Front)” for the
the flywheel housing. backlash measurement.
Table 13 3. Measure the backlash between the idler

Limits for Flywheel Housing Runout and Alignment gear (2) and the crankshaft gear. Refer to
(Total Indicator Reading) Specifications, “Gear Group (Front)” for the
backlash measurement.
Bore of the Housing Maximum Limit (Total
Flange Indicator Reading) 4. Measure the backlash between the fuel injection
410 mm (16.14 inch) 0.25 mm (0.010 inch) pump gear (3) and the idler gear (2). Refer to
Specifications, “Gear Group (Front)” for the
448 mm (17.63 inch) 0.28 mm (0.011 inch) backlash measurement.
76 RENR7967
g01273091
Illustration 75
5. Measure the end play on idler gear (2). Refer

to Disassembly and Assembly, “Idler Gear
- Install” for the correct procedure. Refer to
Specifications, “Gear Group (Front)” for the end
play measurement. g01273828
Illustration 77
Typical example of a crankshaft pulley with poly v-belt
i02545551 (1) Bolt
(2) Thrust block
Crankshaft Pulley - Check (3) Crankshaft adapter
(5) Bolt
The crankshaft pulley is installed on the front of the
crankshaft. There are two types of crankshaft pulley
that can be installed to the engine. Replace the crankshaft pulley if any of the following
conditions exist:
• There is any impact damage to the outer casing.

• There is leakage of the viscous fluid from the cover
plate.
• There is movement of the pulley.

• There is a large amount of gear train wear that is
not caused by lack of oil.
• Analysis of the engine oil has revealed that the

front main bearing is badly worn.
• The engine has had a failure because of a broken

crankshaft.
g01273827
Illustration 76
A standard pulley Check the areas around the holes for the bolts in
(1) Bolt
the crankshaft pulley for cracks or for wear and for
(2) Thrust block damage.
Use the following steps in order to check the
alignment and the runout of the crankshaft pulley:
1. Remove any debris from the front face of the

crankshaft pulley. Remove any debris from the
circumference of the crankshaft pulley.
RENR7967 77
2. Mount the dial indicator on the front cover. Use

the dial indicator to measure the outer face of the
crankshaft pulley. Set the dial indicator to read
0.00 mm (0.00 inch).
3. Rotate the crankshaft at intervals of 45 degrees

and read the dial indicator.
4. The difference between the lower measurements

and the higher measurements that are read on the
dial indicator at all four points must not be more
than 0.18 mm (0.007 inch).
If the reading on the dial indicator is more than

0.18 mm (0.007 inch), inspect the pulley for
damage. If the pulley is damaged, use new parts
for replacement.
5. Move the dial indicator so that the dial indicator

will measure the circumference of the crankshaft
pulley. Set the dial indicator to read 0.00 mm
(0.00 inch).
6. Slowly rotate the crankshaft in order to measure

the runout of the circumference of the crankshaft
pulley. Use the highest reading and the lowest
reading on the dial indicator. The maximum and
the minimum readings on the dial indicator should
not vary more than 0.12 mm (0.005 inch).
If the reading on the dial indicator is more than

0.12 mm (0.005 inch), inspect the pulley for
damage. If the pulley is damaged, use new parts
for replacement.
78 RENR7967
Electrical System
i02544065
Alternator - Test
1. Put the positive lead “+” of a suitable multimeter
on the “B+” terminal of the alternator. Put the
negative “-” lead on the ground terminal or on the
frame of the alternator. Put a suitable ammeter
around the positive output wire of the alternator.
2. Turn off all electrical accessories. Turn off the fuel

to the engine. Crank the engine for 30 seconds.
Wait for two minutes in order to cool the starting
motor. If the electrical system appears to operate
correctly, crank the engine again for 30 seconds.
Note: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a charging
test. If the battery has a low charge, do not perform
this step. Jump start the engine or charge the battery
before the engine is started.
3. Start the engine and run the engine at full throttle.
4. Check the output current of the alternator. The

initial charging current should be equal to the
minimum full load current or greater than the
minimum full load current. Refer to Specifications,
“Alternator and Regulator” for the correct minimum
full load current.
Table 14
Fault Conditions And Possible Causes
Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the Replace the alternator. Turn on all accessories. If the -
specifications Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications.
Turn on all accessories in
order to verify that the voltage
stays within specifications.
The voltage consistently Test the battery. Test the The alternator operates Replace the alternator.
exceeds specifications. alternator again. within the specifications. Test Inspect the battery for
the battery. damage.
RENR7967 79
5. After approximately ten minutes of operating the i02545695

engine at full throttle, the output voltage of the
alternator should be 14.0 ± 0.5 volts for a 12 volt V-Belt - Test
system and 28.0 ± 1 volts for a 24 volt system.
Refer to the Fault Conditions And Possible Table 15
Causes in Table 14. Required Tools
6. After ten minutes of engine operation, the charging Tool Part Number Part Description Qty
current should decrease to approximately 10 A - Belt Tension Gauge 1
amperes. The actual length of time for the
decrease to 10 amperes depends on the following
conditions:
• The battery charge

• The ambient temperature
• The speed of the engine
Refer to the Fault Conditions And Possible
Causes in Table 14.
i01126605
Battery - Test
Most of the tests of the electrical system can be done

on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be
clean, and both components must be tight.
Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
sonnel can be the result.
The battery circuit is an electrical load on the charging

unit. The load is variable because of the condition of
the charge in the battery.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
See Special Instruction, SEHS7633, “Battery Test

Procedure” for the correct procedures to use to
test the battery. This publication also contains the
specifications to use when you test the battery.
80 RENR7967
Table 16
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
1/2 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free If necessary, replace the belt tensioner. Refer
length of belt and check the tension on both belts. to Disassembly and Assembly, “Alternator Belt -
Check and adjust the tension on the tightest belt. Remove and Install”.
To adjust the belt tension, refer to Disassembly and
Assembly, “Alternator - Install”.
i02418527
Poly V-Belt Charging System - Test

NOTICE The condition of charge in the battery at each
Ensure that the engine is stopped before any servicing regular inspection will show if the charging system is
or repair is performed. operating correctly. An adjustment is necessary when
the battery is constantly in a low condition of charge
or a large amount of water is needed. A large amount
To maximize the engine performance, inspect the of water would be more than one ounce of water
poly v-belt (1) for wear and for cracking. Replace the 28 ml per cell per week or per every 100 service
poly v-belt if the belt is worn or damaged. hours. There are no adjustments on maintenance
free batteries.
• If the poly v-belt (1) has more than four cracks per
25.4000 mm (1 inch) the belt must be replaced. When it is possible, make a test of the charging
unit and voltage regulator on the engine, and use
• Check the poly v-belt of cracks, splits, glazing, wiring and components that are a permanent part of
grease, and splitting. the system. Off-engine testing or bench testing will
give a test of the charging unit and voltage regulator
operation. This testing will give an indication of
needed repair. After repairs are made, perform a test
in order to prove that the units have been repaired to
the original condition of operation.
Alternator Regulator
The charging rate of the alternator should be checked
when an alternator is charging the battery too much
or not charging the battery enough.
Alternator output should be 28 ± 1 volt on a 24 volt

system and 14 ± 0.5 volt on a 12 volt system. No
adjustment can be made in order to change the rate
of charge on the alternator regulators. If the rate of
charge is not correct, a replacement of the regulator
is necessary. For individual alternator output, refer to
Specification, “Alternator and Regulator”.
g01216014
Illustration 78
Typical example
To replace the poly v-belt, refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
RENR7967 81
See Special Instruction, REHS0354, “Charging Table 17

System Troubleshooting” for the correct procedures
to use to test the charging system. This publication Typical Voltage Of Electrical System During Cranking
also contains the specifications to use when you test At Various Ambient Temperatures
the charging system. Temperature 12 Volt 24 Volt
System System
i02399802 í23 to í7°C 6 to 8 volts 12 to 16 volts
(í10 to 20°F)
Electric Starting System - Test í7 to 10°C 7 to 9 volts 14 to 18 volts
(20 to 50°F)
10 to 27°C 8 to 10 volts 16 to 24 volts
(50 to 80°F)
General Information
All electrical starting systems have four elements: Table 18 shows the maximum acceptable loss of
voltage in the battery circuit. The battery circuit
supplies high current to the starting motor. The values
• Keyswitch in the table are for engines which have service of
2000 hours or more.
• Start relay
Table 18
• Starting motor solenoid
Maximum Acceptable Voltage Drop In The Starting
• Starting motor Motor Circuit During Cranking
Circuit 12 Volt 24 Volt
Keyswitches have a capacity of 5 to 20 amperes. The System System
coil of a start relay draws about 1 ampere between
test points. The switch contacts of the start relay for Battery post “-” to 0.7 volts 1.4 volts
the starting motor are rated between 100 and 300 the starting motor
terminal “-”
amperes. The start relay can easily switch the load of
5 to 50 amperes for the starting motor solenoid. Drop across the 0.5 volts 1.0 volts
disconnect switch
The starting motor solenoid is a switch with a capacity
Battery post “+” 0.5 volts 1.0 volts
of about 1000 amperes. The starting motor solenoid to the terminal of
supplies power to the starter drive. The starting motor the starting motor
solenoid also engages the pinion to the flywheel. solenoid “+”
The starting motor solenoid has two coils. The Solenoid terminal 0.4 volts 0.8 volts
pull-in coil draws about 40 amperes. The hold-in coil “Bat” to the solenoid
terminal “Mtr”
requires about 5 amperes.
When the magnetic force increases in both coils, Voltage drops that are greater than the amounts
the pinion gear moves toward the ring gear of the in Table 18 are caused most often by the following
flywheel. Then, the solenoid contacts close in order conditions:
to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily • Loose connections
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the • Corroded connections
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Faulty switch contacts
Cranking of the engine continues until current to the
solenoid is stopped by releasing the keyswitch.
Diagnosis Procedure
The procedures for diagnosing the starting motor
Power which is available during cranking varies
are intended to help the technician determine if a
according to the temperature and condition of the
starting motor needs to be replaced or repaired. The
batteries. Table 17 shows the voltages which are
procedures are not intended to cover all possible
expected from a battery at the various temperature
problems and conditions. The procedures serve only
ranges.
as a guide.
82 RENR7967
The current and the voltages that are specified

NOTICE in the Specifications Module are measured
If equipped with electric start, do not crank the engine at a temperature of 27°C (80°F). When the
for more than 30 seconds. Allow the starter to cool for temperature is below 27°C (80°F), the voltage will
two minutes before cranking again. be lower through the starting motor. When the
temperature is below 27°C (80°F), the current
Never turn the disconnect switch off while the engine through the starting motor will be higher. If the
is running. Serious damage to the electrical system current is too great, a problem exists in the starting
can result. motor. Repair the problem or replace the starting
motor.
If the starting motor does not crank or cranks slow, If the current is within the specification, proceed
perform the following procedure: to Step 3.
1. Measure the voltage of the battery. 3. Measure the voltage of the starting motor.
Measure the voltage across the battery posts with a. Use the multimeter in order to measure the
the multimeter when you are cranking the engine voltage of the starting motor, when you are
or attempting to crank the engine. Do not measure cranking or attempting to crank the engine.
the voltage across the cable post clamps.
b. If the voltage is equal to or greater than the
a. If the voltage is equal to or greater than the voltage that is given in Table 17, then the
voltage in Table 17, then go to Step 2. battery and the starting motor cable that goes
to the starting motor are within specifications.
b. The battery voltage is less than the voltage in Go to Step 5.
Table 17.
c. The starting motor voltage is less than the
A low charge in a battery can be caused by voltage specified in Table 17. The voltage drop
several conditions. between the battery and the starting motor is
too great. Go to Step 4.
• Deterioration of the battery
4. Measure the voltage.
• A shorted starting motor
a. Measure the voltage drops in the cranking
• A faulty alternator circuits with the multimeter. Compare the
results with the voltage drops which are
• Loose drive belts allowed in Table 18.
• Current leakage in another part of the b. Voltage drops are equal to the voltage drops
electrical system that are given in Table 18 or the voltage drops
are less than the voltage drops that are given
2. Measure the current that is sent to the starting in Table 18. Go to Step 5 in order to check the
motor solenoid from the positive post of the engine.
battery.
c. The voltage drops are greater than the voltage
Note: If the following conditions exist, do not perform drops that are given in Table 18. The faulty
the test in Step 2 because the starting motor has a component should be repaired or replaced.
problem.
5. Rotate the crankshaft by hand in order to ensure
• The voltage at the battery post is within 2 volts that the crankshaft is not stuck. Check the oil
of the lowest value in the applicable temperature viscosity and any external loads that could affect
range of Table 17. the engine rotation.
• The large starting motor cables get hot. a. If the crankshaft is stuck or difficult to turn,
repair the engine.
Use a suitable ammeter in order to measure the
current. Place the jaws of the ammeter around the b. If the engine is not difficult to turn, go to Step 6.
cable that is connected to the “bat” terminal. Refer
to the Specifications Module, “Starting Motor” for 6. Attempt to crank the starting motor.
the maximum current that is allowed for no load
conditions. a. The starting motor cranks slowly.
RENR7967 83
Remove the starting motor for repair or Table 19

replacement. 12 Volt System
b. The starting motor does not crank. Amp Time (sec)
16.6 Initial
Check for the blocked engagement of the
pinion gear and flywheel ring gear. 12 5.7
9 11.1
Note: Blocked engagement and open solenoid
contacts will give the same electrical symptoms. 7 20
6 60
i02404326
Table 20
Glow Plugs - Test
24 Volt System
Amp Time (sec)
9 Initial
Continuity Check of the Glow Plugs
7 3.3
The following test will check the continuity of the glow 6 5.3
plugs.
3 60
1. Disconnect the power supply and the bus bar.
6. Check the reading on each glow plugs.
2. Use a suitable digital multimeter to check
continuity (resistance). Turn the audible signal on 7. If there is no reading on the ammeter check the
the digital multimeter ON. electrical connections. If the readings on the
ammeter are low replace the faulty glow plug. If
3. Place one probe on the connection for the glow there is still no reading replace the faulty glow
plug and the other probe to a suitable ground. The plug.
digital multimeter should make an audible sound.
Replace the glow plug if there is no continuity.
4. Check the continuity on each the glow plugs.
Checking The Operation of The

Glow Plug
The following test will check the operation of the glow
plugs.
1. Disconnect the power supply and the bus bar.
2. Connect the power supply to only one glow plug.
3. Place a suitable ammeter on the power supply

wire.
4. Connect a suitable digital multimeter to the

terminal on the glow plug and to a suitable ground.
5. Turn the switch to the ON position in order to

activate the glow plugs.
RENR7967 81
See Special Instruction, REHS0354, “Charging Table 17

System Troubleshooting” for the correct procedures
to use to test the charging system. This publication Typical Voltage Of Electrical System During Cranking
also contains the specifications to use when you test At Various Ambient Temperatures
the charging system. Temperature 12 Volt 24 Volt
System System
i02399802 í23 to í7°C 6 to 8 volts 12 to 16 volts
(í10 to 20°F)
Electric Starting System - Test í7 to 10°C 7 to 9 volts 14 to 18 volts
(20 to 50°F)
10 to 27°C 8 to 10 volts 16 to 24 volts
(50 to 80°F)
General Information
All electrical starting systems have four elements: Table 18 shows the maximum acceptable loss of
voltage in the battery circuit. The battery circuit
supplies high current to the starting motor. The values
• Keyswitch in the table are for engines which have service of
2000 hours or more.
• Start relay
Table 18
• Starting motor solenoid
Maximum Acceptable Voltage Drop In The Starting
• Starting motor Motor Circuit During Cranking
Circuit 12 Volt 24 Volt
Keyswitches have a capacity of 5 to 20 amperes. The System System
coil of a start relay draws about 1 ampere between
test points. The switch contacts of the start relay for Battery post “-” to 0.7 volts 1.4 volts
the starting motor are rated between 100 and 300 the starting motor
terminal “-”
amperes. The start relay can easily switch the load of
5 to 50 amperes for the starting motor solenoid. Drop across the 0.5 volts 1.0 volts
disconnect switch
The starting motor solenoid is a switch with a capacity
Battery post “+” 0.5 volts 1.0 volts
of about 1000 amperes. The starting motor solenoid to the terminal of
supplies power to the starter drive. The starting motor the starting motor
solenoid also engages the pinion to the flywheel. solenoid “+”
The starting motor solenoid has two coils. The Solenoid terminal 0.4 volts 0.8 volts
pull-in coil draws about 40 amperes. The hold-in coil “Bat” to the solenoid
terminal “Mtr”
requires about 5 amperes.
When the magnetic force increases in both coils, Voltage drops that are greater than the amounts
the pinion gear moves toward the ring gear of the in Table 18 are caused most often by the following
flywheel. Then, the solenoid contacts close in order conditions:
to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily • Loose connections
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the • Corroded connections
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Faulty switch contacts
Cranking of the engine continues until current to the
solenoid is stopped by releasing the keyswitch.
Diagnosis Procedure
The procedures for diagnosing the starting motor
Power which is available during cranking varies
are intended to help the technician determine if a
according to the temperature and condition of the
starting motor needs to be replaced or repaired. The
batteries. Table 17 shows the voltages which are
procedures are not intended to cover all possible
expected from a battery at the various temperature
problems and conditions. The procedures serve only
ranges.
as a guide.
RENR7967 85
Index Section
Gear Group (Front) - Time..................................... 50

General Information................................................. 4
Glossary of Electronic Control Terms .................... 39
Glow Plugs - Test................................................... 83
Checking The Operation of The Glow Plug ....... 83
Continuity Check of the Glow Plugs................... 83
Important Safety Information ................................... 2

Increased Engine Oil Temperature - Inspect ......... 63
Introduction.............................................................. 4
Lubrication System .......................................... 16, 61
Piston Height - Inspect .......................................... 72

Piston Ring Groove - Inspect................................. 69
Inspect the Clearance of the Piston Ring........... 69
Inspect the Piston and the Piston Rings ............ 69
Inspect the Piston Ring End Gap....................... 69
Power Sources ...................................................... 36
ECM Power Supply............................................ 37
Introduction (Power Supplies)............................ 36
Power supply for the Glow plugs ....................... 39
Power Supply for the Pressure Sensors ............ 38
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 45
Turbocharger - Inspect .......................................... 52
Inspection of the Compressor and the Compressor
Housing ............................................................ 53
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 53
Inspection of the Wastegate .............................. 54
V-Belt - Test ........................................................... 79

Poly V-Belt ......................................................... 80
Valve Depth - Inspect ............................................ 58
Valve Guide - Inspect ............................................ 59
Water Pump - Inspect............................................ 68

Water Temperature Regulator - Test ..................... 67
86 RENR7967
Index Section
RENR7967 87
Index Section
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.

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RENR8913

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Specifications Section When the crankshaft is viewed from the front of

The front of the engine is opposite the flywheel end.

Fuel Injection Lines

Contact with high pressure fuel may cause fluid

Type of combustion ............................ Direct injection

Number of cylinders ................................................ 4

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

Firing order ................................................. 1, 3, 4, 2

Manifold to Injector i02519422

Fuel Injection Pump

Note: Before the pump is removed from the engine

Note: Refer to Systems Operation, Testing

(1) Locking screw

Locking the shaft

Note: The support bracket must be installed after i02519286

Note: Refer to Systems Operation, Testing

(4) Retaining setscrew ................... 30 N·m (22 lb ft)

i02519336 Hand Fuel Priming Pump

Note: Refer to Systems Operation, Testing

(1) The plunger that is hand operated.

Electric fuel Priming Pump

(2) The canister for the fuel filter

Fuel Priming Pump

Note: Refer to Systems Operation, Testing

(1) Diameter of the lifter body .. 18.987 to 19.012 mm

Bore diameter in the cylinder block

Clearance The service limit for both rocker arm

(7) Snap ring

(4) Exhaust rocker arm

Valve Mechanism Cover

Tighten the bolts for the valve mechanism cover in

Cylinder Head Valves

(2) Valve face angle

(3) Valve stem diameter

(5) Valve head

i02505671 Note: The maximum distortion of the bottom face of

Lubricate the threads and the underside of the head

Minimum thickness of cylinder head ....... 100.95 mm

(1) Valve guide bores

(2) Valve depths

Turbocharger The part number for

The movement for the rod actuator ................. 1 mm

Camshaft Camshaft Journals Standard Diameter

Maximum wear on the camshaft journals ... 0.05 mm

Check the camshaft lobes for visible damage. If a

(1) End play of a camshaft ......... 0.126 to 0.558 mm

Maximum permissible end play of a worn

(1) The diameter of the installed camshaft

Engine Oil Filter Base

Engine Oil Cooler Engine Oil Pump

Engines with Balancer Group

(1) Clearance of the outer rotor to the

(2) Clearance of inner rotor to outer

(5) Tighten the idler gear bolt to the following

Note: Set the engine to the TC position. Refer to

Number of lobes (3) End play of rotor assembly

Engine Oil Pressure

Engine Oil Pan

(2) Clearance of inner rotor to outer

Apply Tooling (A) to the cylinder block and to the