KDC 614 Series Engine Shopmanual 1991 SERIES: Cebm614Sho

CEBM614SHO
KDC 614 SERIES ENGINE

SHOPMANUAL
1991 SERIES
Shop Manual
614 Series Engine
1991 Model
KDC 614 Series Engine

Table of Contents
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E
Engine Disassembly and Assembly - Group 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Cylinder Block - Group 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cylinder Head - Group 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rocker Levers - Group 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cam Followers - Group 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel System - Group 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Injectors and Fuel Lines - Group 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lubricating Oil System - Group 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cooling System - Group 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive Units - Group 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Intake System - Group 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust System - Group 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Equipment - Group 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Equipment - Group 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Testing - Group 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instruments and Controls - Group 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mounting Adaptations - Group 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Specifications and Torque Values - Group 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..X
Foreword
This manual contains complete rebuild specifications and information for the 614 Series engines.
The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended kern.
A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be
ordered through your distributor using the form in Section L
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Komatsu Dresser Co. reserves the right to make any changes at any time without obligation. If differences are found
between your engine and the information in this manual, contact your KDC Distributor.
The latest technology and the highest quality components are used to manufacture KDC engines. When replacement parts
are needed, we recommend using only genuine KDC exchange parts.
[Rev. A]
Engine - Exploded View by Groups
GROUP 02
Section i - Introduction
614 Series Page i-l
Section i - Introduction
Section Contents
Page
Aboutthe Manual .......................................................... i-2
General Cleaning Instructions .................................................. i-8

Solvent and Acid Cleaning i-8
Steam Cleaning . . . . . . . i-8
General Repair Instructions i-7
General Safety ‘Instructions i-6
Generic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-4
Glossary of Terms . . . . . . i-9
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-3

Group Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-3
Index . . . . . . . . . . . . . . i-3
Metric Information, . . . . . i-3
Table of Contents . . . . . i-3
Illustrations . . . . . . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-5
About the Manual Section i - Introduction
Page i-2 614 Series
About the Manual

This 614 Series Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and
assembly of components of the 614 Series engines. The manual is divided into sections. Section 00 outlines the
disassembly and assembly of the engine while the other section detail specific components.
The procedures in this manual were developed for a shop environment with engine disassembly and assembly being
performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and
systems. Refer to the Table of Contents (page i-l) for the various groups. The information is presented in very basic terms
to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when
needed.
Each group contains the following in sequence:
l An Alphabetical Table of Contents (Index).
l Exploded view(s) of all the components in the group.
l General Information Section(s) containing the basic service, maintenance, and design information necessary to assist
in the rebuild of the engine or a component.
l Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an
engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These
repairs depend on the length of time an engine has been in service and the condition of the parts.
Section i - Introduction How To Use This Manual
614 Series Page i-3
How To Use This Manual

Table of Contents
The Table of Contents in the front of the manual contains a quick page reference for each group number.
Group Contents
Each group contains the following information:
A group index page at the beginning of each group to quickly aid in locating the information desired.
General information to aid in rebuilding the component and an explanation of design change differences.
Step-by-step rebuild instructions for disassembly, cleaning, inspection, and assembly of the component.
Symbols which represent the action outlined in the instructions. The definitions of the symbols, appear on pages
i-5 through i-8.
Index
An alphabetical index is in the back of the manual to aid in locating specific information.
Metric Information,
Both metric and U.S. customary values are used in this manual. The metric value is listed first, followed by the U.S.
customary in brackets. An example is 88°C [148” F].
About the Manual Section i - Introduction
Page i-4 614 Series
Generic Symbols
The following group of symbols have been used in this manual to help communicate the intent of the instructions.
When one of the symbols appears, it conveys the meaning defined below.
WARNING - Serious personal injury or extensive property damage can result if the warning instructions
are not followed.
CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged if
the caution instructions are not followed,
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step,
INSPECTION is required,
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque,
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information,
The component weighs 23 kg [50 lb] or more, To avoid personal injury, use a hoist or get assistance
to lift the component.
Section i - Introduction Illustration
614 Series Page i-5
Illustrations
The illustrations used in the “Repair Sections” of this manual

are intended to give an example of a problem, and to show
what to look for and where the problem can be found. Some
0@
of the illustrations are “generic” and might not look exactly
like the engine or parts used in your application. The
illustrations can contain symbols to indicate an action
required, and an acceptable or not acceptable condition.
The illustrations are intended to show repair or replacement

procedures. The illustration can differ from your application,
but the procedure given will be the same.
kn9cswt
General Safety Instructions Section i - lntrodcution
Page i-6 614 Series
General Safety Instructions

Important Safety Notice
A WARNING (g
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting
motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s compartment
or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler
cap and relieve the pressure from the cooling system.
Do not work on any thing that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure,
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines
in a well ventilated area.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not
be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with
skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact,
immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A
PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes
and compartments.
Always use tools that are in good condition, Make sure you understand how to use them before performing any
service work. Use ONLY genuine KDC replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners, Do not use a fastener, of
lessor quality if replacements are necessary.
Section i - Introduction General Repair instructions
614 Series Page i-7
General Repair Instructions

This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices
performed to quality standards.
0 Komatus Dresser Co. does not recommend or authorize any modifications or repairs to engines or
components except for those detailed in KDC Service Information. In particular, unauthorized repair to
safety-related components can cause personal Injury. Below Is a partial listing of components classified as
safety-related:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing Turbocharger Oil Drain Line(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted In the Procedures.
Follow the manufacturer’s recommendations for cleaning solvents and there substances used during the repair of
the engine. Always use good safety practices with tools and equipment.
Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine and its components must be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
Perform the Inspections Specified in the Procedures.
Use Genuine KDC Service Parts and Assemblies
Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
The assembly instructions have been wriien to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new KDC components.
All of the repair services described in this manual are available from all KDC Distributors.
Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from your KDC
Distruibutor. Refer to Section L, Literature, for ordering instructions.
General Cleaning Instructions Section i - lntrodcution
Page i-8 614 Series
General Cleaning Instructions

Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Komatsu Dresser Company does
not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions.
Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95”
Celsius [60 to 200” Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning
solution will give the best results.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam
clean the parts before putting them in the cleaning tank.
Warning: The use of acid can be extremely dangerous to personnel, and can damage the machinery. Always
provide a tank of strong soda water as a neutralizing agent.
Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The
rustproofing compound must be removed from the parts before installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way
to clean the oil drillings.
Warning: Wear protective clothing to prevent personal Injury from the high pressure and extreme heat.
Do not steam clean the following parts:
1. Electrical Components
2. Wiring
3. Injectors
4. Fuel Pump
5. Belts and Hoses
6. Bearings
Section i - Introduction Glossary of Terms
614 Series Page i-9
Glossary of Terms
Definition
A. C.: Alternating Current
AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is
sufficient intake manifold pressure to allow for complete combustion.
ATDC: After Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving downward on the power stroke or intake stroke.
BDC: Bottom Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is at its lowest position in the cylinder.
BTDC: Before Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving upward on the compression stroke or exhaust stroke.
Circumferential Direction: In the direction of a circle in respect to the centerline of a round part or a bore.
Concentricity: A measurement of the difference between the centers of either two or more parts or the
bores In one part.
Silicone Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive and
sealant material having high heat and oil resistance, and low compression set.,
Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corning, Silastic
732, Loctite Superflex, General Electric RTV108 and Three Bond Sealant.
D. C.: Direct Current
Dye Penetrant Method: A method used to check for cracks in a part by using a dye penetrant and a developer.
Use crack detection kii, Part No. 3375432, or its equivalent.
End Clearance: The clearance in an assembly determined by pushing the shaft in an axial direction one
way and then pushing the shaft the other way.
E. S. N. Engine Serial Number
Hammer: A hand tool consisting of a hard steel head on a handle.
I. D.: Inside Diameter
Loctite 290: A single component, anaerobic, polyester resin, liquid sealant compound that hardens
between closely fiied metal surfaces producing a tough. hard bond. Equivalent products
are KDC 1232 273 Hl and Perma-Lok HL 126.
Loctite 609: A single component anaerobic, liquid adhesive that meets or exceeds the requirements
of MIL-R46082A (MN) TYPEl.
Some of the equivalent products are KDC 634 018 Cl, Loctite 601 and Permabond HL
138.
Lubriplate 105: A mineral oil base grease with calcium soap (2 percent to 6 percent), and zinc oxide (2
percent to 4 percent) additives.
Magnetic Particle Inspection: A method of checking for cracks in either steel or iron parts. This method requires a
Magnaflux or equivalent machine that imparts a magnetic field on the part being checked.
Mallet: A hand tool consisting of a soft head, either wood, plastic, lead, brass, or rawhide, on
a handle.
Glossary of Terms Section i - lntrodcution
Page i-10 614 Series
Defintion
MAX: Maximum allowed
MIN: Minimum allowed
No.: Number
O.D.: Outside Diameter
OS: Oversize
Protrusion: The difference in the height between two parts in the assembled state.
STD: Standard
TC: Torque Converter; used when referring to the torque converter cooler.
TDC: Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The
piston is at its highest position in the cylinder. The rod journal is pointing straight up
toward the piston.
T.I.R.: Total Indicator Runout; used when measuring the concentricity or the runout. The T.I.R.
refers to the total movement of the needle on a dial indicator, from the most negative
reading to the most positive reading.
Water Pump Grease: A premium high temperature grease that will lubricate antifriction bearings continually from
minus 40” C [minus 40” F] to plus 150” C [plus 350” F]. Some of the greases meeting
this requirement are Aeroshell No. 5, Chevron SRI, Amoco Rykon Premium No. 2, Texaco
Premium RB, and Shell Dolium R. Aeroshell No. 5 is not compatible with the other
greases and must not be mixed. Aeroshell No. 5 is used on new engines and
components.
Section E - Engine and Component Identification
614 Series Page E-l
Section E - Engine and Component Identification

Section Contents
Page
Engine Diagrams ............................................................ 6
Engine Identification ......................................................... 2

Engine Dataplate ........................................................... 2
Fuel Injection Pump Dataplate .................................................. 3
General Engine Specifications ................................................... 4

Cooling System ............................................................ 5
Fuel System .............................................................. 5
General Engine Data ........................................................ 4
Intake Air and Exhaust System .................................................. 5
Lubrication System .......................................................... 4
Engine Identification Section E - Engine and Component Identification
Page E-2 614 Series
Engine Identification
Engine Dataplate
The engine dataplate shows specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.
NOTE: The engine dataplate must not be changed unless
approved by KDC.
ENGINE SERIAL NO.

KbmatsuDresser
LIBERTWILLE. ILLINOIS. L30040 “.S.A
TIMING TDC KOC PIN
0
Warning Injury Raault
May And VALVE LASH COLD INT. EXH. RATED HP AT RPM
Warranty It Voided If Fuel Rate
RPM Or Altltudas Exceed Plubllshed FIRING ORDER FUEL RATE AT RATED HP MM3/STROKE
Maxlmum Valuaa For This Hod@1 And
A,,pllcatton.
E.C.S. KDC MODEL
MADE IN U.S.A.
E2BWOOOl
Engine Dataplate
The KDC model designation represent the basic design

and configuration of your engine.
Example Engine Model Name:
6 14TA
(1) (2) (3) (1) Number of cylinders
(2) Displacement per cylinder/100 in cc
(3) Type of aspiration:
T = Turbocharged
A = Aftercooled
Section E - Engine and Component Identification Injection Pump Dataplate
614 Series Page E-3
Fuel Injection Pump Dataplate

The injection pump dataplate is located on the side of the
injection pump. It provides information for fuel pump
calibration.
The Bosch Injection pump dataplate contains:

1. Pump Serial Number
2. Bosch Ten Digit Number
3. Bosch Designation Code
9 400 230 097

PES6AlOOD320/3RS
The vendor part number for the fuel pump-governor

combination is located on the governor dataplate.
The Bosch governor dataplate contains:

1. Bosch Governor Designation Code.
2. Vendor Pump Part Number
S/RSV425 llOOAOC2190-8R
CDC-NO 390 6541

General Engine Specifications Section E - Engine Component Identification
Page E-4 614 Series
General Engine Specifications
General Engine Data
Bore ................................................................ 114mm[449in]

Stroke ............................................................... 135 mm [5.32 in]
Displacement ........................................................ 8.27 liters [504.5 in31
Compression ratio
614 ...................................................................... 16.4:1
614T ..................................................................... 17.3:1
614A ..................................................................... 16.5:1
Firing order ................................................................ l-5-3-6-2-4
Valve clearance
Intake ........................................................... 0.30 mm [0.012 in]
Exhaust .......................................................... .0.61 mm [0.024 in]
Engine rotation (viewed from front of engine) .......................................... Clockwise
Aspiration
614 ............................................................. Naturally Aspirated
614T ............................................................... Turbocharged
614A .................................................... Turbocharged and Aftercooled
Engine weight (with standard accessories)
Dry weight ............................................... 570 to 606 kg 11256 to 1335 lb]
Wet weight ............................................... 599 to 636 kg [1320 to 1402 lb]
Lubrication System
Oil pressure
At idle (minimum allowable) ............................. ................. 69 kPa (10 psi]
At rated speed (minimum allowable) ....................... ................. 207 kPa 130 psi]
Differential pressure to open oil filter bypass valve ................ ................. 138 kPa [20 psi]
Oil flow at rated speed (less flow though pressure regulator .......... ............. 106.8 Ipm [28.2 gpm]
Oil temperature at rated speed ............................. ..... .98.9” to 126.6”C 1210” to 26O”F]
Oil temperature thermostat
Fully open ........................................ . . . . . . . . . . . . . . . . . . 116°C [241”F]
Closed ........................................... . . . . . . . . . . . . . . . . . . 104°C [219”F]
Oil pan capacity (all engines) (high - low) ...................... . . 18.9 to 15.1 liters [20 to 16 U.S. Qts.]
Total system capacity
614.. ........................................... .......... 23.6 liters [25.0 U.S. Qts.]
614T ............................................ ........... 23.8 liters 125.2 U.S. Qts]
Section E - Engine Component Identification General Engine Specifications
614 Series Page E-5
Cooling System
Thermstats
Begins to open .............................................. 81” to 83°C [178” to 182”F]
Fully open ............................................................ 95°C [203”F]
Top tank temperature

Maximum allowable ..................................................... 100°C [212”F]
Minimum recommended ................................................... 70°C [158”F]
Pressure cap for 99°C [21O”F] system ........................................... 50 kPa [7 psi]
Pressure cap for 104°C [22O”F] system ......................................... 103 kPa [15 psi]
Water Pressure (Upper manifold) at 2000 RPM engine speed .................. 103 to 276 kPa [15 to 40 psi]
Coolant flow (thermostats fully opened, engine speed 2000 RPM) ....................... 258 Ipm [68 gpm]
Coolant capacity (engine only)

614, 614T ..................................................... 9.9 liters [lo.5 U.S. C&s.]
614A ....................................................... 10.9 liters [11.5 U.S. Cts.]
Intake Air and Exhaust System

Maximum allowable intake restriction at rated speed and load (with dirty air filter element)
614 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 cm He0 [20 in H,O]
614T,614A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5cmH,0[25inH20]
Maximum turbocharger outlet restriction at rated speed and load
614T,614A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2mmHg[3inHg]
614T,614A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6cmH20[40inH20]
Fuel System
Fuel transfer pump maximum inlet restriction
614, 614T ...................................................... 95 mm Hg [3.75 in Hg]
614TA ........................................................ 153 mm Hg [6.0 in Hg]
Fuel transfer pump maximum output pressure

614, 614T, 614A ...................................................... 172 kPa [25 psi]
Minimum pressure to fuel pump inlet ........................................ 1.2 Bar [18 psi]
Minimum flow to fuel injection pump ........................... 250 percent of rated fuel requirement
Fuel filter restriction (maximum pressure drop across filters) ............................. 35 kPa [5 psi]
Fuel pump gallery pressure .................................................. 140 kPa [20 psi]

Fuel return restriction (maximum) ........................................ 518 mm Hg [20.4 in Hg]
Engine Diagram Section E - Engine Component Identification
Page E-6 614 Series
Engine Diagrams
The illustration which follow show the locations of the major external engine components, the filters, and other service
and maintenance points. Some external components will be at different location for different engines.
High Pressure
Fuel Lines %[inch]NPTF (Air)
Front Liiing
Fuel/Water
W x 1 G[inch]UNF
Tap for Magnetic
Front Engine
Mounting Bracket
FUEL PUMP SIDE VIEW

Section E - Engine Component Identification Engine Diagram
614 Series Page E-7
Turbochamer
Crankcase
VentTube
Rear View
TurbocharW Engine Air
Front View
Engine Diagram Section E - Engine Component Identification
614 Series
Page E-8
Turbocharger Turbocharger
Wastegate Actuator
Turbocharger
Exhaust Outlet
Provision for
Coolant Heater -
Provision for
Cab Heater
Turbocharger
Oil Drain
Turbocharger Side View

Engine Disassembly and Assembly - Group 00
614 Series Page O-1

Section Contents
Page
Engine - Assembly .......................................................... O-39

AFC Tube - Installation ..................................................... O-l 12
Aftercooler - Installation ..................................................... O-97
Air Compressor - Installation ................................................. O-119
Air Crossover Tube - Installation ............................................... O-101
Alternator Brace - Installation ................................................. O-104
Alternator - Installation ..................................................... O-l 03
Alternator Mounting Bracket - Installation ......................................... O-103
Belt Tensioner Bracket - Installation ............................................ O-105
Belt Tensioner - Installation .................................................. O-105
Camshaft - Installation ...................................................... O-65
Connecting Rod Bolt - Installation ............................................... O-54
Coolant Filter - Installation ................................................... O-102
Coolant Heater - Installation ................................................... O-82
Coolant Inlet Connection - Installation ........................................... O-103
Coolant Outlet Connection - Installation .......................................... O-102
Coolant Vent Fitting - Installation .............................................. O-102
Coolant Vent Petcock - Installation ............................................. O-102
Coolant Vent Tube - Installation ............................................... O-103
Crankcase Breather Tube - Installation ............................................ O-95
Crankshaft - Installation ...................................................... O-47
Cylinder Block - Installation onto Engine Rebuild Stand ................................ O-39
Cylinder Head - Installation . . . . . .............................................. O-85
Cylinder Liner - Installation .............................................. O-40
Drive Belt - Installation . . . : : : : : ............................................. O-118
Engine Lifting Bracket - Installation
Engine - Removal from the Rebuild stan~.::::::::::::::::::::::::::::::::::::::::.O~~~
Engine Support, Front - Installation ............................................. O-118
Exhaust Manifold - Installation . . . .............................................. o-97
Fan Hub Assembly - Installation . . ............................................. O-l 06
Flywheel Bore Runout Measurement ............................................. O-79
Flywheel Face Runout Measurement ............................................. O-81
Flywheel Housing - Installation ................................................. O-72
Flywheel - Installation ....................................................... O-77
Fuel Drain Manifold - Installation ................................................ O-96
Fuel Filter Head - Installation ................................................. O-111
Fuel Filter - Installation ..................................................... O-l 11
Fuel Injection Pump - Installation .............................................. O-106
Fuel Injection Pump Supply Line - Installation ...................................... O-110
Fuel Lines, High Pressure - Installation .......................................... O-112
Fuel Lines, Low Pressure - Installation ........................................... O-119
Fuel Pump Solenoid - Installation .............................................. O-119
Fuel Transfer Pump - Installation .............................................. O-118
Gear Cover - Installation .................................................... O-116
Gear Housing - Installation ................................................... O-62
Injector - Installation ........................................................ O-95
Intake Manifold Cover - Installation .............................................. O-96
Lubricating Oil Cooler - Installation .............................................. O-84
Lubricating Oil Filter - Installation ............................................... O-85
Lubricating Oil Pan - Installation ................................................ O-68
Lubricating Oil Pump - Installation .............................................. O-64
Lubricating Oil Suction Tube - Installation ......................................... O-68
Main Bearing (Lower) - Installation .............................................. O-47
Main Bearing (Upper) - Installation .............................................. O-46
Main Bearing Cap - Installation ................................................. O-47
Piston Assembly - Installation .................................................. O-58
Piston Cooling Nozzle - Installation .............................................. O-45
Page O-2 614 Series
Piston Pin - Installation ...................................................... O-54

Piston Ring End Gap - Measurement ............................................. O-55
Piston Ring - Installation ..................................................... O-56
Push Rod - Installation ...................................................... O-89
Rocker Lever and Shaft - Assembly ............................................. O-89
Rocker Lever Assembly - Installation ............................................. O-91
Seal, Front Crankshaft - Installation ............................................. O-113
Seal, Rear Crankshaft - Installation .............................................. O-51
Starting Motor - Installation ................................................... O-82
Tachometer Drive - Installation ................................................ O-l 17
Thermostat and Housing - Installation ........................................... O-101
Timing Pin Assembly - Installation ............................................... O-69
Turbocharger Exhaust Outlet Connection - Installation ................................ O-l 01
Turbocharger - Installation .................................................... O-98
Turbocharger Oil Drain Tube - Installation ......................................... O-99
Turbocharger Oil Supply Hose - Installation ....................................... O-100
Valve Arrangement ......................................................... O-93
Valve Clearance - Adjustment .................................................. O-92
Valve Cover - Installation ..................................................... O-94
Valve Tappet - Installation .................................................... O-44
Vibration Damper - Installation ................................................ O-l 17
Water Pump - Installation .................................................... O-67
Engine Accessories - Installation ............................................... O-l 21
Engine - Disassembly ....................................................... O-9

AFC Tube - Removal ....................................................... O-12
Aftercooler - Removal ....................................................... O-17
Air Compressor - Removal .................................................... O-14
Air Crossover Tube - Removal ................................................. O-17
Alternator Brace - Removal ................................................... O-21
Alternator Mounting Bracket - Removal ........................................... O-22
Alternator - Removal ........................................................ O-22
Belt Tensioner Bracket - Removal ............................................... O-21
Belt Tensioner - Removal .................................................... O-21
Camshaft - Removal ........................................................ O-28
Coolant - Draining ......................................................... O-10
Coolant Filter - Removal ..................................................... O-10
Coolant Heater - Removal .................................................... O-26
Coolant Inlet Connection - Removal ............................................. O-24
Coolant Outlet Connection - Removal o-22
Coolant Vent Petcock - Removal ... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : O-23
Coolant Vent Tube Fitting - Removal ............................................. O-23
Coolant Vent Tube - Removal O-23
CrankcaseBreatherTube-Removal’:::::::::::::::::::::::::::::::::::::::::::::0-16
Crankshaft - Removal ....................................................... O-36
Cylinder Head - Removal .................................................... O-23
Cylinder Liner Carbon Deposits - Removal ......................................... O-32
Cylinder Liner Protrusion - Checking ............................................. O-37
Cylinder Liner - Removal ..................................................... O-37
Drive Belt - Removal ....................................................... O-21
Engine - Installation onto Engine Rebuild Stand ..................................... O-15
Engine Liiing Equipment and Brackets ........................................... O-9
Engine - Preparation for Steam Cleaning .......................................... O-9
Engine - Steam Cleaning ..................................................... O-9
Engine Support, Front - Removal ............................................... O-31
Exhaust Manifold - Removal ................................................... O-20
Expansion Plug - Removal .................................................... O-39
Expansion Plug - Replacement ................................................. O-38
Fan Hub Assembly - Removal ................................................. O-24
Flywheel Housing - Removal .................................................. O-27
Flywheel - Removal ........................................................ O-27
Fuel Drain Manifold - Removal ................................................. O-18
Fuel Filter Head - Removal ................................................... O-11
Fuel Filter - Removal ....................................................... O-l 1
Fuel Injection Pump - Removal ................................................. O-13
614 Series Page O-3
Fuel Injection Pump Supply Line - Removal ........................................ O-12

Fuel Lines, High Pressure - Removal ............................................. O-12
Fuel Lines, Low Pressure - Removal ............................................. O-11
Fuel Pump Solenoid - Removal ................................................ O-15
Fuel Transfer Pump - Removal ................................................. O-11
Gear Cover - Removal ...................................................... O-26
Gear Housing - Removal ..................................................... O-31
Injector - Removal ......................................................... O-18
Intake Manifold Cover - Removal ............................................... O-17
Lubricating Oil Cooler - Removal ............................................... O-24
Lubricating Oil - Draining .................................................... O-10
Lubricating Oil Filter - Removal ................................................ O-10
Lubricating Oil Pan - Removal ................................................. O-27
Lubricating Oil Pump Gear Backlash - Measurement .................................. O-30
Lubricating Oil Pump - Removal ................................................ O-31
Lubricating Oil Suction Tube - Removal ........................................... O-27
Main Bearing (Lower) - Removal ................................................ O-36
Main Bearing (Upper) - Removal ................................................ O-36
Main Bearing Cap - Removal .................................................. O-35
Piston Assembly - Removal ................................................... O-33
Piston Cooling Nozzle - Removal ............................................... O-36
Piston Pin - Removal ....................................................... O-34
Piston Ring - Removal ...................................................... O-35
Push Rod - Removal ....................................................... O-19
Rocker Lever Assembly - Removal .............................................. O-19
Seal, Front Crankshaft - Removal ............................................... O-26
Seal, Rear Crankshaft - Removal ............................................... O-28
Starting Motor - Removal .................................................... O-26
Tachometer Drive - Removal .................................................. O-13
Thermostat and Housing - Removal ............................................. O-22
Turbocharger Exhaust Outlet Connection - Removal ................................... O-16
Turbocharger Oil Drain Tube - Removal ........................................... O-20
Turbocharger Oil Supply Hose - Removal ......................................... O-20
Turbocharger - Removal ..................................................... O-20
Valve Cover - Removal ...................................................... O-18
Valve Tappet - Removal ..................................................... O-29
Vibration Damper - Removal .................................................. O-25
Wastegate Actuator Hose - Removal ............................................. O-16
Water Pump - Removal ...................................................... O-25
Cylinder Block - Removal from Engine Rebuild Stand .................................. O-39
Engine Disassembly and Assembly - Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-4
General Information ......................................................... O-8

Disassembly ............................................................. O-8
Assembly ............................................................... O-8
Engine Disassembly and Assembly - Service Tools Engine Disassembly and Assembly - Group 00
Page O-4 614 Series
Engine Disassembly and Assembly - Service Tools
The following special tools are recommended to perform procedures in Group 00. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.
Used to remove drive pulleys, impellers, air compressor

counterweights, etc.
Install cylinder liner in cylinder block.
Attaches to crankshaft flange to provide measuring of flywheel

and flywheel housing runout with dial bore gauge.
Dial Bore Gauge Kit
Used to measure internal diameter bores from 78.5 mm [3.09

in] to 2.032 mm [8.0 in].
Universal Cylinder Liner Puller
Remove cylinder liners from cylinder block. Requires Part No.

3822786, Cylinder Liner Puller Plate.
Engine Disassembly and Assembly - Group 00 Engine Disassembly and Assembly - Service Tools
614 Series Page 0-5
Tool No. Tool Description Tool Illustration
Used to remove and install lubricating oil filter.
Support cylinder block during engine rebuild. Used with Part

No. 3822807, Adapter Plate.
Nylon Lifting Sling
Aid in removal and installation of crankshaft, flywheel and other

heavy components.
Universal Cylinder Liner Puller
Remove cylinder liners from the cylinder block. Requires two of

Part No. 3376649, Puller Arm Extension Feet.
Dial Indicator and Sleeve Assembly
Use with Part No. ST-1325 Dial Gauge Attachment to measure

flywheel and flywheel housing runout. Use with Magnetic Base,
Part No. 3377399, to measure gear end clearance and
Engine Barring Tool
Used to rotate the crankshaft.
Magnetic Base Dial Indicator Holder
Used with Part No. 3378050, Dial Indicator and Sleeve
Cylinder Liner Clamp Set (includes two clamps)
Used to clamp the liner into the bore of the cylinder block.
Engine Disassembly and Assembly - Service Tools Engine Disassembly and Assembly - Group 00
Page O-6 614 Series
Used to liti the engine.
For mounting the engine to Part No. 3375194, Engine Rebuild
Piston Ring Expander
Used to install piston rings onto pistons without damaging or

distorting the rings.
Injection Pump Drive Gear Puller
Used to pull the injection pump gear.
Used to pull injectors.
Used to compress the piston rings while installing the pistons

into the cylinder bores.
Used to torque high pressure fuel line nuts on A and MW

Bosch fuel injection pumps. Size: 17mm, 3/8 in. drive.
Used for sealing “T” joints and front gear cover.

Engine Disassembly and Assembly - Group 00 Engine Disassembly and Assembly - Service Tools
614 Series Page O-7
Tool No. Tool DescriDtion Tool Illustration
Measure cylinder liner protrusion on the cylinder block.
Used for torquing capscrews by the “torque plus angle”
Install the front crankshaft oil seal wear sleeve.
Fuel Injection Pump Mounting To
Remove and install the fuel injection pump inboard mounting w ¶lB
General Information Engine Disassembly and Assembly - Group 00
Page O-8 614 Series
General Information
These procedures apply to all 614 Series engines. The differences between engine models due to the application, the
optional equipment on an engine, and the year an engine was built are included in the instructions. Omit the steps that
do not apply to the engine being rebuilt.
A Warning: A Warning statement is included for any component or assembly that weighs more than 23 kg
[50 lb]. To avoid personal injury, use a hoist or get assistance when removing or installing these parts.
A Cautiion: All fasteners are given in metric measurements.

a Caution states that a fastener has left-hand threads.
All fasteners have right-hand threads unless
Disassembly
The instructions in this procedure are organized in a logical sequence to disassemble an engine. This is not the only
sequence to disassemble an engine. Certain parts must be removed in the sequence indicated. Use this sequence until
you become familiar with the engine.
Discard all gaskets, seals, hoses, filters, and o-rings. Keep these parts if they are needed for a failure analysis.
Label, tag, or mark the parts for location as the parts are removed. This will help identify the parts that can be involved
in a failure and will simplify the assembly procedure.
Label, tag, mark, or photograph all special equipment prior to the removal from an engine. This engine assembly
procedure does not include the installation of special optional equipment.
Use a mallet when force is required to remove certain parts. Make sure all of the fasteners are removed before using
force.
Avoid as much dirt as possible during disassembly. The accumulation of additional dirt will make it more difficult to clean
the components.
Assembly
This procedure assumes that all of the components and assemblies have been cleaned, replaced, or rebuilt and are ready
to be installed on the engine.
Torque values are listed in each step. If a torque value is not specified, use the chart listed in the Specifications Section,
Group 18, to determine the correct torque value.
Many of the gaskets and o-rings are manufactured from a material designed to absorb oil. These gaskets will enlarge and
provide a tight seal after coming in contact with oil. Use ONLY a recommended contact adhesive or a vegetable based
oil to install these parts.
When replacing capscrews, always use one of the same configuration, either Metric or U.S. Customary. To prevent
damage to the engine or component, make sure the replacement capscrew is the same dimension, length and grade as
the capscrew removed.
Engine Disassembly and Assembly - Group 00 Engine - Disassembly (O-01)
614 Series Page 0-9
Engine - Disassembly (O-01)

Engine Lifting Equipment and Brackets
A
Warning: The engine lifting equipment must be designed
to safely lift the engine as an assembly. The dry weight
of the engine with standard accessories is 606 kg [1335
Ibl.
Use a properly rated hoist and engine lifting fixture, such as
Part No. 3822152, attached to the engine mounted lifting RI
brackets to lift the engine.
Install the engine on two suitable engine support stands.
Engine - Preparation for Steam Cleaning

Install plastic caps or tape on all engine openings to prevent @!I!@
moisture and dirt from entering the engine: Cover all @
electrical components. This will prevent water damage.
Engine - Steam Cleaning
A
Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Steam clean and dry with compressed air.
Engine - Disassembly (O-01) Engine Disassembly and Assembly - Group 00
Page O-10 614 Series
Lubricating Oil - Draining

17 mm
NOTE: The total system lubricating oil capacity including the
lubricating oil filter is 23.8 liters [25.2 U.S. CM.].
Remove the drain plug and discard the drain plug sealing
washer.
Drain the lubricating oil.
op9pxma
Coolant - Draining
Open the draincock at the bottom of the lubricating oil cooler
housing.
Coolant Filter - Removal

90-95 mm Filter Wrench
Remove and discard the coolant filter.
Lubricating Oil Filter - Removal

Part No. 3375049 Filter Wrench
Remove and discard the engine oil filter if not needed for a
failure analysis.
614 Series Page 0-l 1
Fuel Filter - Removal

76-60 mm Filter Wrench, 90-95 mm Filter Wrench
Remove and discard the fuel filters and the sealing rings.
Fuel Filter Head - Removal

24 mm
Remove the fuel filter head and discard the o-rings.
Fuel Lines, Low Pressure - Removal

20, 19, 17 and 14 mm
Disconnect the low pressure fuel lines.
NOTE: To avoid damage to the fuel transfer pump, use two
wrenches when loosening the low pressure line.
Discard all copper washers.
Fuel Transfer Pump - Removal

10 mm
Remove the fuel transfer pump.
Fuel Lines, High Pressure - Removal
RI 17 mm and 19 mm
Remove the high pressure fuel lines.
@ l
Caution: Cover the injectors and fuel pump high pressure

A outlet connections to avoid damage from contamination.
Fuel Injection Pump Supply Line - Removal

17 mm and 19 mm
Remove the fuel injection pump supply line and the fuel return
line.
AFC Tube - Removal

13 mm, 17 mm
Remove the AFC tube.
614 Series Page O-13
Fuel Injection Pump - Removal

22 mm (PESGA Fuel Injection Pump)
27 mm (PESGMW Fuel injection Pump)
30 mm (PESGP Fuel Injection Pump)
Remove the nut and lock washer from the fuel iniection
.
pump shaft.
Part No. 3823259 Fuel Pump Gear Puller

Pull the fuel injection pump drive gear loose from the shaft.
13 mm
If the engine is equipped with a PESGP fuel injection pump,
the support brackets must be removed.
15 mm, Part No. 3823956 Fuel Pump Mounting Tool Kii

Remove the four mounting nuts.
Remove the fuel injection pump.
Air Compressor - Removal

Remove the inlet and outlet air connections from the air
compressor.
15/16 Inch
Remove the inlet and outlet coolant lines from the air
compressor.
9/16 Inch
Remove the oil supply line.
19 mm, 15 mm, 14 mm
Remove the air compressor support bracket and capscrews. •xl
Remove the air compressor.
cp9bkma
Fuel Pump Solenoid - Removal

10 mm
Disconnect the fuel shutoff solenoid wiring. RI
Remove the hitch
shutoff solenoid.
pin clip, mounting capscrews and fuel
c%
0
Engine - Installation onto Engine Rebuild Stand

Part No. 3822512 Engine Lifting Fixture
NOTE: The dry weight of the engine is 606 kg [1335 lb]. Use
an engine lifting bracket, such as Part No. 3822512, to lift the
engine.
Use four (l/2 x 13 x l-1/2 inch) grade 5 capscrews to install

the Part No. 3822607, Adapter Plate, onto the Part No.
3375194, Engine Rebuild Stand.
Torque Value: 95 Nom [70 ft-lb]
Use four Ml0 x 1.5 x 20 mm and two M8 x 12.5 x 20 mm

capscrews to install the adapter plate to the side of the cylinder
block.
Capscrew Capscrew Size Torque Value

Location
A M8 24 Nom [18 ft-lb]
B, C Ml0 40 Nom [30 ft-lb]
Turbocharger Exhaust Outlet Connection -

Removal
7/16 inch, 15 mm
Remove the turbocharger exhaust outlet connection.
Wastegate Actuator Hose - Removal

Screwdriver
Remove the wastegate hose.
Crankcase Breather Tube - Removal

13 mm, 18 mm
Remove the crankcase breather tube support bracket
capscrews (A) and (B).
614 Series
Page O-17
Air Crossover Tube - Removal

Screwdriver
Remove the air crossover tube.
Intake Manifold Cover - Removal

10 mm
Remove the air intake cover plate.
Aftercooler - Removal
8 mm
Remove the coolant supply tube (1) and coolant return tube
(2).
10 mm I I I
Remove the aftercooler housing and gasket.

Fuel Drain Manifold - Removal

10 mm
Remove the fuel drain manifold. Discard the sealing washers.
Injector - Removal
13 mm, Part No. 3823276 Injector Puller
Remove the injectors.
Remove and discard the sealing washers.
fiSwam
Valve Cover - Removal

15 mm
Remove the valve cover.
614 Series
Page O-19
Remove and discard the valve cover seal and capscrew
o-rings.
Rocker Lever Assembly - Removal

14 mm Screwdriver
Loosen the rocker lever adjusting screw locknuts and loosen Ezl
the adjusting screws until they stop.
10 mm
Remove the rocker lever assemblies and oil manifold.
Push Rod - Removal

Remove the push rods.
Turbocharger Oil Supply Hose - Removal
Exl 16 mm
Remove the turbocharger oil supply line.
69
l
Turbocharger Oil Drain Tube - Removal

13 mm, Screwdriver
Remove the turbocharger oil drain tube.
Turbocharger - Removal
15 mm
Remove the turbocharger.
Exhaust Manifold - Removal
RI 15 mm
Remove the exhaust manifold.
@l
Drive Belt - Removal

3/8 inch Square Drive
Remove the drive belt.
Belt Tensioner - Removal

15 mm
Remove the belt tensioner.
Belt Tensioner Bracket - Removal

5 mm Hex Wrench
Remove the belt tensioner bracket.
Alternator Brace - Removal

13 and 19 mm
Remove the alternator brace capscrew (A).
Remove the tail support bracket capscrew (B).
Alternator - Removal
RI 15, 18 and 19 mm
Remove the alternator mounting capscrews and nuts.
69l Remove the alternator.
Alternator Mounting Bracket - Removal

13 mm
Exl Remove the alternator mounting bracket.
Coolant Outlet Connection - Removal

13 mm
Remove the coolant outlet connection.
Thermostat and Housing - Removal
RI 13 mm
Remove the thermostat housing and thermostats.
c%
0
Coolant Vent Tube - Removal

7116 inch
Remove the coolant vent tube.
Coolant Vent Petcock - Removal

9/16 inch
Remove the coolant vent petcock.
Coolant Vent Tube Fitting - Removal

9/16 inch
Remove the l/8 inch brass fiiing from the cylinder head. E2l
Cylinder Head - Removal

16 mm
Loosen and remove the cylinder head capscrews in the
illustrated sequence.
- Front
kn3csoa
The component weighs 74 kg [163 lb]. To avoid personal

injury, use a hoist or get assistance to remove the cylinder
head.
To prevent damage to the combustion face, make sure the

head is removed in a direct upward motion.
Lubricating Oil Cooler - Removal

10 mm
NOTE: Due to the design of the present production lubricating
oil cooler cover, there is approximately 0.7 liter to.75 U.S. Qts.]
lubricating oil that does not drain when the system is drained.
Place a container under the cooler to catch the oil when the
cover is removed.
Remove the oil cooler cover, element and gaskets.
Coolant Inlet Connection - Removal

Screwdriver
Remove the coolant inlet connection.
Fan Hub Assembly - Removal

13 and 10 mm
Remove the fan hub assembly.
614 Series
Page O-25
Water Pump - Removal

13 mm
Remove the water pump.
Remove and discard the o-ring.
Part No. 3377371 Engine Barring Gear

Use the engine barring tool to prevent the engine from Ezl
rotating when loosening the damper capscrews.
Vibration Damper - Removal

21 mm
Remove the vibration damper.

Engine - Disassembly (O-01) 614 Series
Page O-26
sear Cover - Removal
IO mm
3emove the gear cover.
Seal, Front Crankshaft - Removal

Hammer, Punch
Drive or press the seal out of the gear cover.
ac9sema
Starting Motor - Removal

16 mm
Remove the starting motor.
Coolant Heater - Removal

Remove the engine coolant heater.
614Series Page 9-27
Flywheel - Removal
19 mm
Remove two capscrews 180 degrees apart. Install two
M12X1.25X90 mm guide pins.
NOTE: If a clutch is used in the equipment, the threads in
the clutch pressure plate mounting capscrew holes can be
metric or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size and install
two “T-handles” in the flywheel at points (1) and (2).
Remove the remaining six flywheel mounting capscrews.
Remove the flywheel from the guide pins.
Flywheel Housing - Removal

15 mm
Remove the flywheel housing.
Lubricating Oil Pan - Removal

10 mm
Rotate the engine on the rebuild stand and remove the oil
pan and gasket.
Lubricating Oil Suction Tube - Removal

8 mm
Remove the suction tube and gasket.
Seal, Rear Crankshaft - Removal

8mm
Remove the rear seal housing and gasket.
Support the rear seal housing and press/drive out the seal.
Camshaft - Removal
Gear Backlash Measurement
Position an indicator on a tooth of the camshaft gear.
Note the camshaft gear backlash (A). Mark the camshaft gear
and crankshaft gear for further analysis if backlash exceeds
limits.
Camshaft Gear Backlash Limits

mm in
0.152 MIN 0.006
0.38 MAX 0.015
NOTE: Hold the adjoining gear from moving when checking

backlash or the reading will be the total for both gears.
ks9geia
0a9
Rotate the crankshaft to align the timing marks before trying
to remove the camshaft.
15 mm
Remove the camshaft thrust plate capscrews.
Remove the camshaft and thrust plate from the cylinder

block. Take care not to drop the thrust plate.
Refer to Procedure l-22 for camshaft cleaning and
inspection.
Valve Tappet - Removal

Electric Pencil q
r
J
Remove the valve tappets and mark for location as
illustrated.
Caution: When reusing the camshaft and tappets, the 4
%
tappets must be matched to their companion lobe on the
camshaft to prevent accelerated camshaft wear. Discard
tappets that were not marked during removal. A .
<.-Jq
J
kf900mt
Lubricating Oil Pump Gear Backlash -

Measurement
Position the indicator on a tooth of the gear.
Note the drive gear backlash. Mark the drive gear and idler
gear for additional analysis if the limits are exceeded.
backlash or the reading will be the total of both gears.
Oil Pump Drive Gear Backlash (A)

mm in
0.08 MIN 0.003
0.45 MAX 0.018
Id9geia
Position the indicator on a tooth of the pump idler gear.
Note the idler gear backlash. Mark the idler gear and
crankshaft gear for additional analysis if the limits are
exceeded.
Oil Pump Idler Gear Backlash (A)

mm in
0.08 MIN 0.003
0.45 MAX 0.018
Id9idia
c.-
Lubricating Oil Pump - Removal
13 mm
Remove the lubricating oil pump.
Refer to Procedure 7-08 for cleaning and inspection.
Engine Support, Front - Removal

15 mm
Remove the front engine support.
E2l
c%
0
Gear Housing - Removal

10 mm
Remove the capscrews, gear housing and gasket.
NOTE: Do not remove the timing pin assembly unless the

gear housing is being replaced. Refer to page O-69 in this e
section for replacing the timing pin assembly.
Pin
I o\ I , I Cylinder Liner Carbon Deposits - Removal
Caution: Do not use emery cloth or sandpaper to remove
carbon from the cylinder liners and cylinder block cylinder
head mounting surface. Aluminum oxide or silicon particles
from emery cloth or sandpaper can cause serious engine
damage.
Rotate the crankshaft to expose the carbon ridge above the
ring travel area in the cylinder liner.
Warning: When performing the following procedures, wear

eye protection. Also, if the brush is motor driven, make sure
the wire brush is rated for the RPM being used.
Use a rotary wire brush to remove the carbon ring from the top
of the cylinder liner.
Do not use the steel wire wheel in the piston travel area.
Operate the wheel in a circular motion to remove the deposits.
Use lint-free paper to remove all the broken wire bristles and
loose carbon from the cylinders.
q
a If a rotary wire brush is not available, use a scraper that has
an aluminum blade.
Use a fine fibrous abrasive pad such as Scotch-BriieQ 7448,
Part No. 3823258 or equivalent, to remove the remaining
carbon.
Piston Assembly - Removal

Mark each connecting rod cap according to cylinder.
NOTE: Engine serial numbers beginning with 3040000 have a
number from 1 to 7 stamped on the balancing lug. This
number is used as a connecting rod weight sort code and
does not designate cylinder number.
cxSOOia
To avoid confusion when disassembling an engine beginning

with serial number 3040000, use double digits to identify the
cylinder number from which the connecting rod was
removed. Mark the connecting rod for cylinder No. 1 with 11,
cylinder No. 2 with 22 and so on.
I cx900lb
Also, the code used on engines beginning with serial number

3040000 to mark the connecting rod and connecting rod cap
as a matched set is a two letter code, such as AA, AB, AC,
etc. Instead of an alpha-number code.
Mark each piston according to the corresponding cylinder.

Catuion: Do not use a stamp on anodized pistons. A
stamp will damage the anodized coating. Use a scribe to
mark the pistons.
A
19 mm, Plastic Hammer

Remove the nuts from the connecting rod capscrews.
Tap the connecting rod bolts to loosen the connecting rod cap.
Remove the lower connecting rod bearing. Mark the cylinder
number and the letter ‘I” (lower) in the flat surface of the
bearing tang.
_ cxibema
Catch the piston with one hand while pushing the connecting
rod and piston assembly out of the cylinder bore. Care must
be taken not to damage the crankshaft journal.
Place the connecting rod and piston assemblies on a rack to

protect them from damage.
NOTE: The piston and connecting rod assemblies must be
installed in the same cylinder number they were removed from
to be sure proper fii of worn mating surfaces if parts are used
again.
Use a tag to mark the cylinder number each piston and
connecting rod assembly was removed from.
Piston Pin - Removal

Use internal snap ring pliers to remove the retaining rings from
both sides of the piston.
Remove the piston pin.
NOTE: Heating the piston is not required.
Piston Ring - Removal

Part No. 3823137 Piston Ring Expander
Use piston ring expander, Part No. 3823137, to remove the
piston rings. -
Place a tag on the piston rings and record the cylinder
number of the piston on the tag.
pi900fb
I _I
Main Bearing Cap - Removal

19 mm
Rotate the engine to a horizontal position and remove the Ezl
main bearing cap capscrews.
0
C%
0a3
The main bearing caps should be numbered.
Use a steel stamp to mark any main bearing caps without a
number before the main bearing cap is removed.
mb900wa
Remove the main bearing caps.

Do not pry on the main bearing caps to free them from
the cylinder block.
Use two main bearing cap capscrews to “wiggle” the main
bearing cap loose, being careful not to damage the
capscrew threads.
Main Bearing (Lower) - Removal

l Remove the lower main bearing shells from the main bearing
@ caps.
Mark the main bearing shells with the journal number they were
removed from in the flat surface of the main bearing tang.
Do not mark on the main bearing to crankshaft mating surface.
Damage to the engine can result if the main bearings are used
again.
Crankshaft - Removal
The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.
Lift the crankshaft straight up to avoid damage to the
crankshaft or cylinder block.
Install the Part No. 3375957, Nylon Lifting Sling, around the
number “3” and “4” rod bearing journals.
Attach the sling to a hoist and remove the crankshaft.
Main Bearing (Upper) - Removal

l Use both thumbs to remove the upper main bearing shells.
@
Mark the main bearing shells with the journal number they were
removed from in the flat surface of the main bearing tang.
Do not mark on the main bearing to crankshaft mating surface.
Damage to the engine can result if the main bearings are used
again.
Piston Cooling Nozzle - Removal
Eil 3/16 Inch Pin Punch

Remove and discard the piston cooling nozzles.
*
CB
qn900ma
Cylinder Liner Protrusion - Checking

Part No. 3823495 Liner Protrusion Gauge
RI
Cylinder liner protrusion is the distance the cylinder liner
protrudes above the block face. Before removing the liners,
check the protrusion in the “unclamped” state.
Cylinder Liner Protrusion

mm in
0.025 MIN 0.001
0.122 MAX 0.0043
If the cylinder liner protrusion is out of limits, it will be

necessary to machine the counterbore and add shims to
restore to the original specifications.
Cylinder Liner - Removal
Two service tools are available to remove the cylinder liners:
l Universal liner puller, Part No. 3376015, with extension
foot, Part No. 3376649.
l Universal liner puller, Part No. 3375629 with plate, Part
No. 3376649.
Part No. 3376015 Cylinder Liner Puller

Caution: The cylinder liner puller must be installed and RI
A
used as described to avoid damage to the cylinder block.
The puller must not contact the block casting at points
(t), (2), (3), and (4).
Insert the cylinder liner puller in the top of the cylinder block.
NOTE: The cylinder liner puller must be centered on the top

of the cylinder block.
Turn the cylinder liner puller jackscrew clockwise to loosen
the cylinder liner from the cylinder block.
Use both hands to remove the cylinder liner.
Part No. 3375629 Universal Liner Puller

Caution: The cylinder liner puller must be installed and
used as described to avoid damage to the cylinder block.
The cylinder liner puller plate must be parallel to the main
bearing saddles and must not overlap the cylinder liner
outside diameter.
insert the cylinder liner puller in the top of the cylinder block.
NOTE: The cylinder liner puller must be centered on the top

Turn the cylinder liner puller jackscrew clockwise to loosen the
cylinder liner from the cylinder block.
Use both hands to remove the cylinder liner.
Use DykerrP or equivalent to mark the cylinder number on

each cylinder liner.
Remove and discard the o-ring.
Expansion Plug - Replacement

All expansion plugs must be replaced if the component is
cleaned in a “hot tank”, spray washer or similar equipment.
This cleaning activiiy can interrupt the sealing capacity of the
sealant.
Engine Disassembly and Assembly - Group 00 Engine Assembly (O-02)
Expansion Plug - Removal

To remove expansion plugs: l
@
0 Use a hammer and center punch to mark the
expansion plug for drilling.
l Drill a 3 mm [l/8 inch] hole in the expansion plug.
0 Use a dent puller to remove the expansion plug.
Refer to Group 01 for expansion plug location and ,@,
identification.
Cylinder Block - Removal from Engine Rebuild

Stand
13 mm
Remove the cylinder block from the engine rebuild stand.
RI
personal injury, use a hoist or get assistance to lift the 69 l
component.
Refer to
inspection
Procedures l-05 and
l-06 for cleaning and ab
ck9tom
Engine - Assembly (O-02)

Cylinder Block - Installation onto Engine
Rebuild Stand
NOTE: The component weighs 23 kg [50 lb] or more. To
avoid personal injury, use a hoist or get assistance to lilt
the component.
Use a hoist and Part No. 3375957, Engine Liiing Sling, to lift
the cylinder block.
Use Part No. 3822607, Adapter Plate, with Part No. 3375194,
Engine Rebuild Stand.
Engine Assembly (O-02) Engine Disassembly and Assemlby - Group 00
Page 0-40 614 Series
Use four Ml 0X15X20 mm and two M8X1.25X20 mm capscrews

to install the adapter plate to the fuel injection pump side of the
cylinder block:
Capscrew Location Capscrew Size Torque Value

A M8 24 Nom [18 ft-lb]
B, C Ml0 40 Nom [30 ft-lb]
Cylinder Liner - Installation

Caution: Clean all deposits and debris from sealing
surfaces A, B and C. Use Scotch-BriW 7446 or equivalent
and cleaning solvent to polish the surfaces. However, due
to the critical machined tolerances, care should be taken
not to remove any additional material.
Refer to Procedure l-06 for cylinder liner counterbore
inspection.
Lubricate surfaces A and B with clean 15W-40 engine oil.
ck9brga
NOTE: When reusing liners, install them in the same cylinder

from which they were removed and rotate them 45 degrees
(l/8 turn) from their original position. When correctly installed,
any cylinder liner pitting should be positioned as illustrated so
the pitted surface is rotated away from the location where
pitting occurs.
&&clean 15W-40 engine oil to coat the cylinder liner o-ring
Install the o-ring seal on the cylinder liner.

NOTE: The cylinder liner must be installed within 15 minutes
after applying oil to the cylinder liner o-ring seal.
Make sure the cylinder liner o-ring is not twisted or damaged
during installation.
Part No. ST-1229 Cylinder Liner Driver

Install the cylinder liner into the cylinder block. +
Use cylinder liner driver, Part No. ST-1229, and a leather
mallet to drive the cylinder liner into the bore.
NOTE: If the cylinder liner does not rest on the cylinder
block counterbore seat, remove the cylinder liner. Inspect the
counterbore seat and cylinder liner for nicks, burrs, or dirt.
Install the cylinder liner again.
0
@
Part No. 3822503 Liner Clamps

Use two cylinder head capscrews and position the two
cylinder liner clamps as illustrated.
Tighten the capscrews.
Remove the clamps and repeat this procedure until all
cylinder liners have been clamped and released.
Part No. 3823495 Liner Protrusion Gauge

Cylinder liner protrusion is the distance the cylinder liner •l
protrudes above the block face. Measure the cylinder liner
protrusion at four points, 90 degrees apart:
Cylinder Liner Protrusion

mm in
0.025 MIN 0.001
0.122 MAX 0.0048
NOTE: If the cylinder liner protrusion varies more than 0.025

mm [O.OOlO inch] for 180 degrees:
l Install and tighten the cylinder liner clamps again.
l Inspect the cylinder liner protrusion again.
I
L__________I
iI
7
3
ck9cyda
63
l
NOTE: If the cylinder liner protrusion
0.025 mm [O.OOlO inch]:
l Remove the cylinder liner.
still varies more than
l Inspect the cylinder liner sealing edge for burrs, dirt or

damage.
Replace the cylinder liner if it is damaged.
Install the cylinder liner again.
Inspect the cylinder liner protrusion.
bp2cysb
Service Tip: If the out-of-limit condition is minimal, tolerance

stack-up may allow the cylinder liner protrusion limits to be
obtained by installing other new cylinder liners in the out-of-limit
bore.
NOTE: If the cylinder liner protrusion still does not meet the
specifications, machine the cylinder block liner counterbore
and add counterbore shims to adjust the cylinder liner
protrusion to the proper specifications.
Use a feeler gauge to inspect the cylinder liner to block

clearance at the four block casting points.
Cylinder Liner to Block Clearance

mm in
0.229 MIN 0.009
NOTE: If the cylinder liner to block clearance is less than

0.229 mm [0.009 inch]:
l Remove the cylinder liner.
0aiD
l Inspect the cylinder liner and cylinder block for dirt or
damage.
l Replace the cylinder liner if it is damaged.

l Install the cylinder liner again.
Measure the cylinder liner bore for out-of-roundness at points

“C,,, ‘CD”, “E”,
“F” and “G”. Measure each point in the
direction “AA” and “BB”. The cylinder liner bore must not be
more than 0.04 mm [O.OOlS inch] out-of-round.
NOTE: If the cylinder liner bore is more than 0.04 mm [O.OOlS

inch] out-of-round:
l Remove the cylinder liner so the cylinder block liner
bore can be measured.
ckZcyji
Valve Tappet - Installation
A
Caution: Observe the following guidelines for tappet
installation:
l When reusing the camshaft and tappets, the tappet
must be matched to their companion lobe on the
camshaft. If the tappets were not marked upon
removal, they must not be reused.
l Do not install used tappets with a new camshaft.
l Mixing of new and used tappets when reusing the
camshaft is permissible, providing. the used tappets
are kept with their companion lobes of the camshaft.
614 Series Page 0-45
Lubricate the tappet heads, stem and sockets with

Lubriplatem 105.
Install the valve tappets.
Piston Cooling Nozzle - Installation

23 mm
Remove the main bearing caps.
l/2 Inch Center Punch

Install the. piston cooling nozzles even with or below the
bearing saddle surface.
NOTE: Due to the positioning and spray angle of the
nozzles, there are no bores needed for the No. 3 main
bearing saddle.
0a3
Be sure spray holes are clean and open.
NOTE: Be sure the piston cooling nozzle hole is not
damaged during cleaning.
Main Bearing (Upper) - Installation

The upper bearings contain two oil holes. The lower bearings
do not. Both upper and lower main bearings are marked on the
back to indicate either standard (STD) or oversize (OS)
thickness.
NOTE: Main bearing shells are available for crankshafts which
are machined 0.50 mm [0.020-inch] undersize the original
diameter. Crankshafts which are machined undersize in the
connecting rod and main bearing journals are marked on the
front counterweight. If the crankshaft is marked, check the main
bearing and connecting rod shell part numbers to make sure
the correct bearing size is used.
Caution: The tang (1) on the bearing shell must be in the

slot (2) of the bearing saddle to correctly position the
bearing and prevent engine damage.
Install the upper main bearing shells.
NOTE: If used bearing shells are to be installed, each must be
installed in its original location in the engine. The main bearing
journal numbers should have been marked in the bearing tangs
during disassembly.
\u mb9OOwb
Install the combination thrust/main bearing in the center

journal.
u
+4
Lubricate the main bearings with Lubriplatem
Do not lubricate the back of the main bearing.
105.
Caution: Prevent dirt from mixing with the lubricant. Dirty

A lubricant will accelerate main bearing wear.
Crankshaft - Installation
Use a lint-free cloth. Clean the crankshaft bearing journals.
q
\

personal injury, use a hoist or get assistance to l’ifl the
component.
Use a hoist and Part No. 3375957, Nylon Liiing Sling.
Install the sling around the numbers “3” and “4” connecting @
rod bearing journals. BY
Do not damage or move the main bearing shells when the
crankshaft is installed.
Install the crankshaft.
Main Bearing (Lower) - Installation

Install the lower main bearing shells with the tang (1) in the
slot (2) of the main bearing cap.
0a3
Use Lubriplate@ 105, or equivalent, to coat the inside
diameter of the main bearing shells.
mbebehb
Main Bearing Cap - Installation

The main bearing caps are numbered for location. No. 1
starts with the front of the block and the numbers face the
camshaft side of the engine.
0a9
When correctly installed, the main bearing tangs (slots)
should both be on the same side.
Engine Disassembly and Assemlby - Group 00
Engine Assembly (O-02) 614 Series
Page 0-46
Position the main bearings and main bearing caps onto the
crankshaft.
The thrust bearing journal does not have tangs or slots. Care
should be taken to be sure the number stamped on the main
bearing cap is positioned to the camshaft side of the engine.
Lubricate the main bearing capscrew threads and underside of

the capscrew head with clean engine oil.
mbQcswa
Small Plastic or Rubber Mallet

Tap the main bearing cap gently into position.
Make sure the main bearing is still aligned with the cap.
When seated, the main bearing capscrews can be threaded in
by hand.
19 mm
Tighten the main bearing
illustrated sequence.
capscrews evenly following the RI
Torque Value:
Step
0@a
50 Nom [ 37 ft-lb]
: 119 Nom [ 66ft-lb]
3 176 Nom [129 ft-lb]
- Front
mb3csha
The crankshaft must rotate freely after the main bearings

have been torqued.
Check the main bearing installations and the size of the main
bearings if the crankshaft does not rotate freely. 0a3
Measure the end clearance of the crankshaft as follows:

l Install a dial indicator such as Part No. 3376050, to the
oil pan flange.
l Put the tip of the gauge against the crankshaft
counterweight.
l Push the crankshaft toward the rear of the cylinder
block.
l Set the dial indicator at zero.

l Push the crankshaft toward the front of the cylinder
block.
l If the end clearance is less than 0.16 mm [O.O06inch],
do the following:
l Loosen the main bearing capscrews one turn.

l Push the crankshaft toward the front and then toward
the rear of the cylinder block.
Tighten the main bearing capscrews in the sequence shown to

the torque values listed in the installation procedure.
- Front
mb9csha
Measure the crankshaft end clearance. The end clearance

specification for a new or machined crankshaft with new thrust
bearings is 0.16 mm [0.006-inch] to 0.33 mm [0.013-inch].
NOTE: Crankshafts that have been machined on the thrust

0.25 mm[O.OlO in.] 8 bearing surfaces are marked for oversize thrust bearings on the
rear crankshaft counterweight. If the crankshaft counterweight
is marked, check the thrust bearing part number to make sure
the correct bearing size is used.
Example: 0.010 = 0.25 mm [O.OlO-inch]
If the crankshaft end clearance is more than 0.54 mm

[0.021-inch] on a used engine, the crankshaft must be
removed from the engine and repaired.
Seal, Rear Crankshaft - Installation

Use crocus cloth to remove any rust or other deposits from
the crankshaft flange.
Use a clean cloth to clean the rear crankshaft flange.
NOTE: Do not use any kind of lubricant to install the seal.
The oil seal must be installed with the lip of the seal and the
crankshaft clean and dry.
Visually inspect the seal contact area for wear. If the seal
contact area has a groove worn deep enough to feel with a
fingernail or sharp object, it will be necessary to install a
wear sleeve over the sealing surface.
Refer to the following procedure:
NOTE: The combination oil seal/wear sleeve replacement kit

contains discardable seal installation alignment tools.
Install the wear sleeve on the crankshaft with the chamfered

end toward the cylinder block.
kssslhd I
Hammer, Wear Sleeve Installation Tool

Drive the wear sleeve onto the crankshaft flange.
The repair sleeve must be placed over the worn area, not just
bottomed or left flush with the end of the shaft.
ks9tohc
Use a clean, dry cloth to clean the wear sleeve surface.
ks9seed
NOTE: There are two rear seal configurations used; one for dry
flywheel housings (1) and one for wet housings (2). The seal
for dry housings has an aluminum case with urethane coated
O.D.. The seal for wet housings has a steel case with silicone
coated O.D.. Refer to the appropriate Parts Manual for the
correct part number.
NOTE: The oil seal for a wet flywheel housing requires soap
on the outside diameter of the seal case. Nothing is required
on the outside diameter of the seal case for dry housings.
ks9sewa
Hammer, Seal Installation Tool

NOTE: Do not use any kind of lubricant to install the seal.
The oil seal must be installed with the lip of the seal and the
wear sleeve clean and dry.
Install the seal in the rear cover.
Use the installation tool and hammer to push the seal into
the rear cover until the outside diameter of the seal
installation tool contacts the rear cover.
ks9sewb
Install two M6Xl.OOX50 mm guide pins 160 degrees apart

into the rear of the cylinder block.
Install the rear cover and gasket over the guide pins.
rc9piha
10 mm
Align the rear cover to the crankshaft with the alignment tool
provided in the seal kit. Be sure the rear cover is even with
both sides of the oil pan rail on the cylinder block.
Remove the guide pins.

Install the rear cover capscrews and tighten.
Torque Value: 9 Nom [80 in-lb]
Remove the rear crankshaft seal pilot tool.
Trim the rear cover gasket even with the oil pan mounting
surface.
Make sure the rear cover gasket trim does not fall into the
engine.
Connecting Rod Bolt - Installation

Plastic Hammer
Tap the connecting rod bolts in until the head is aligned and
seated on the flat machined surface of the connecting rod.
cx9bosa
Piston Pin - Installation

Use clean 15W-40 engine oil to coat the connecting rod piston
pin bore and piston pin.
cx9OOwb
Caution: Be sure “Front” marking on piston and the

numbers on the connecting rod and connecting rod cap
are oriented as illustrated.
Snap Ring Pliers

NOTE: Pistons do not require heating to install the piston
pin; however, the pistons do need to be at room temperature
or above.
NOTE: The retaining ring must be seated completely in the
piston pin bore to prevent engine damage during engine
operation.
Install a new retaining ring into the piston pin bore.
Align the piston pin bore of the connecting rod with the
piston pin bore of the piston and install the piston pin. Install
the second retaining ring. pi9COab
Piston Ring End Gap - Measurement

Rotate the engine on the rebuild stand until the crankshaft is
vertical and the crank gear is facing upward.
NOTE: If the engine is rotated more than 90 degrees, the
valve tappets can fall out.
To check the piston ring gap, use the top end of a piston to
align the piston rings in the wear area of the cylinder liner in
which they will be used.
r
A = 89 mm [3.5 inches]
pi9rita
Use a feeler gauge to measure the piston ring gap. Replace the
ring if it does not meet the following specifications:
New Piston Ring Gap

mm in
Top: 0.40 MIN 0.016
0.70 MAX 0.026
Intermediate: 0.40 MIN 0.016
0.70 MAX 0.028
Oil Control: 0.30 MIN 0.012
0.60 MAX 0.024
NOTE: Add 0.09 mm [0.004 in] for every 0.03 mm [O.OOl in] of
cylinder liner bore wear up to the maximum worn limit.
Identify the ring sets for installation in the cylinder in which the
end gap was measured.
pi9riga
Piston Ring - Installation

The top surface of the upper and intermediate rings are
identified either with the word “TOP” or a supplier identification
mark, such as a dot. Assemble with the word “TOP” or the
supplier mark facing upward.
The bottom or oil control ring can be installed with either side
up.
NOTE: The two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil ring. Do
not overlap the ends of the expander ring.
pi9riha
Part No. 3823137 Piston Ring Expander

Install the rings on the piston.
Position the oil ring expander in the oil control ring groove.
Install the oil control ring with the end gap opposite the ends
on the expander.
NOTE: There are two different types of intermediate rings

used:
Rectangular (A)
Reverse Twist (B)
Refer to the appropriate Parts Manual to see which type of e
rings are required.
Install the intermediate ring.
Install the top ring.
/ DiSOl ac
Piston Assembly - Installation

Install the connecting rod bearing shells into both the
connecting rod and connecting rod cap. Make sure the tang
on the conecting rod bearing shell is in the slot of the
connecting rod cap and connecting rod.
Connecting rod bearings are marked on the back to indicate
either standard (STD) or oversize (OS) thickness.
NOTE: If used connecting rod bearing shells are to be
installed, each bearing shell must be installed in its original
location.
Caution: Do not lubricate the back of the connecting rod

bearing shells.
Caution: Prevent dirt from mixing with the lubricant. Dirty
lubricant will accelerate connecting rod bearing wear.
Lubricate the connecting rod bearings with a light film of
Lubriplatem 105.
cx900wa
Lubricate the piston rings and piston skirts with clean 15W-40
engine oil.
Position the ring gaps 120 degrees apart.
pt9rihb
Part No. 3623290 Piston Ring Compressor

Compress the rings using the piston ring compressor.
q
Use a clean lint-free cloth to clean the crankshaft bearing
journals. \
Use a clean lint-free cloth to wipe the cylinder bores.

\
Lubricate the cylinder bore with clean 15W-40 engine oil. B
Part No. 3377371 Engine Barring Tool

Rotate the crankshaft to position the journal for the d-
04iD
connecting rod, which is being installed, at bottom dead
center (BDC).
Caution: Be sure “Front” marking on the piston and the

numbers on the connecting rod and connecting rod cap are
oriented as illustrated.
Caution: Use care when installing the piston and connecting

rod so the cylinder bore is not damaged.
Position the piston and connecting rod assembly into the
cylinder bore with the word “Front” on the piston toward the
front of the cylinder block.
Hold the piston ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the cylinder
liner.
NOTE: If the piston does not move freely, remove the piston
and inspect for broken or damaged rings.
Push the piston into the bore until the top of the piston is
approximately 50 mm [2 inches] below the top of the bore.
Then, pull the connecting rod onto the crankshaft journal.
Use clean 15W-40 engine oil to lubricate the threads of the

connecting rod capscrews.
04B
NOTE: The numbers marked on the connecting rod and the
connecting rod cap must be the same. The tang slot side of
the conecting rod cap must be on the same side as the
tang slot in the connecting rod when the connecting rod cap
is installed.
Use Lubriplate@ 105, or equivalent, to coat the inside
diameter of the connecting rod bearing shell.
Install the connecting rod bearing in the connecting rod cap.
Install the connecting rod cap and start the connecting rod
nuts.
Use clean 15W-40 engine oil to lubricate the connecting rod

nuts.
19 mm
Alternately tighten the connecting rod nuts to pull the RI
connecting rod cap into position.
19 mm Socket, Torque Wrench

Tighten the connecting rod cap to the connecting rod.
Torque Value:
Step 1 - 40 Nom [30 ft-lb]
0
Shake the connecting rod after tightening to verify side
a3 clearance.
Measure the side clearance between the connecting rod and

the crankshaft.
Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.33 MAX 0.013
1.. _-AZ cx9OOdb I
NOTE: The crankshaft must rotate freely.

Check for freedom of rotation as the connecting rod caps are
installed. If the crankshaft does not rotate freely, check the
installation of the connecting rod bearings and the bearing size.
/ -I- -1
I
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Gear Housing - Installation

Install the two gear housing dowel pins, if removed.
NOTE: The tapered end of the dowel fits into the cylinder
block. Drive the pin to the bottom of the hole.
gh9doha 1
Position the gasket onto the alignment dowels.
15 mm
If the fuel injection pump studs are damaged or being
installed in a new housing, coat the threads with Loctitem
242 and use two nuts locked together to remove and install.
gh900wE
Small Chisel and Hammer

If the gear housing is being replaced, remove the engine
dataplate and install on the new gear housing. Refer to
Procedure l-25.
13 mm
Caution: If a new gear housing or other than the original
gear housing is installed, the timing pin assembly must
be accurately located. Refer to page O-69 in this section.
Install the gear housing and capscrews.
Torque Value:
M8 capscrews 24 Nom [18 f-t-lb]
Ml 2 capscrews 60 Nom [44 ft-lb]
Trim the gear housing gasket off even with the oil pan rail.
NOTE: Do not let the gasket trimmings fall into the engine.
Lubricating Oil Pump - Installation

Lubricate the lubricating oil pump with clean 15W-40 engine oil.
NOTE: Fill the lubricating oil pump with oil during installation
to aid in quicker oil suction when the engine is started.
Make sure the’ lubricating oil pump idler gear pin is installed
into the locating bore of the cylinder block.
The back plate on the lubricating oil pump seats against the
bottom of the bore in the cylinder block. When the pump is
correctly installed, the flange on the pump will not touch the
cylinder block.
13 mm
Tighten the lubricating oil pump capscrews in the sequence
shown.
Torque Value:
Step 1 - 5 N l m [44 in-lb]
Use a dial indicator with a magnetic base to measure the

idler gear backlash.
Measure the gear backlash.

NOTE: Hold the adjoining gears from moving when checking
Oil Pump and Idler Gear Backlash (A 81 B)

mm in
0.08 MIN 0.003
0.45 MAX 0.018
I ip9gena
Camshaft - Installation
Lubricate the camshaft bores with Lubriplatem 105. 0+A
Refer to Group 01 for camshaft bushing installation.
Service Tip: The crankshaft should be positioned with the *
No. 1 cylinder at approximately top dead center (TDC), so
the camshaft does not hit the crankshaft counterweights
during installation.
q
Lubricate the camshaft journals and lobes, and thrust plate with
LL , LubriplateTM 105.
Install the camshaft and gear assembly into the cylinder block
up to the last journal.
0
Align the timing marks on the camshaft with the timing mark on
a9 the crankshaft.
Caution: If the engine is in the vertical position, be sure the
A camshaft assembly does not drop on your fingers when

installing the thrust plate.
13 mm
Install the thrust plate capscrews.
Torque Value: 24 Nom [18 Mb]
Measure the camshaft end clearance.

End clearance is controlled by the thickness of the thrust
plate and the groove in the camshaft.
Camshaft End Clearance

mm in
0.12 MIN 0.0047
0.46 MAX 0.018
Be sure the camshaft backlash is correct.

Use an indicator to measure backlash.
Camshaft Gear Backlash Limits

mm in
0.152 MIN 0.006
0.38 MAX 0.015
Water Pump - Installation

13 mm
Install an o-ring into the groove on the water pump mounting
flange.
Position the water pump assembly into the pump cavity of
the cylinder block. Align mounting holes and install two
capscrews at 1l:OO o’clock and 4:00 o’clock position.
The capscrew located in the 7:00 o’clock position is longer
and is used for the alternator support brace, it will be
installed along with the alternator.
wo900ht
Lubricating Oil Suction Tube - Installation

Position the new lubricating oil suction tube gasket onto the
cylinder block.
Make sure the gasket is aligned correctly with the oil suction
hole in the cylinder block.
6mm
Install the lubricating oil suction tube over the gasket and align
the mounting holes.
Use the following sequence to tighten the capscrews:
Torque Value:
Step A Suction Tube to Block 9 Nom [88 in-lb]
Step B Brace to Block 9 Nom [88 in-lb]
Step C Brace to Suction Tube 9 Nom [88 in-lb]
Lubricating Oil Pan - Installation

Apply a 2 mm [l/16 inch] bead of Three Bond Sealant, Part
No. 3823494, to joints between the lubricating oil pan rail, gear
housing and rear seal housing.
NOTE: The lubricating oil pan and gasket must be installed
within 15 minutes after applying Three Bond Sealant.
Apply a 2 mm [l/16 inch] bead of Three Bond Sealant, Part

No. 3823494, to both sides of the new lubricating oil pan
gasket.
Install the gasket.
Install the lubricating oil pan.
10 mm
Assemble the washers and capscrews to secure
lubricating oil pan as illustrated.
21 17 13 9 5 1 3 7 11 15 19 23
Tighten all capscrews in the sequence shown in
accompanying chart.
Torque Value: 24 Nom [18 it-lb]
opscsoa
17 mm
Install the drain plug and a new drain plug sealing washer.
Torque Value: 80 N l m [59 ft-lb]
0%
Timing Pin Assembly - Installation

Caution: The timing pin assembly is precisely located on
;;;~y~;d;;;~~ fo correspond to top dead center (TDC) A
. . Timing Pin
I
The timing pin assembly must be relocated if a gear housing
_other than the original is installed.
Failure to locate the timing pin assembly to TDC for cylinder
No. 1 will result in incorrect injection timing.
11 T-Gear Housing
13 mm, 18 mm
Rotate the engine on the engine stand to the horizontal
position.
To relocate the timing pin assembly, temporarily install the

vibration damper and a pointer fabricated from No. 16 gauge
wire. Put a flat washer between the pointer and gear housing
to prevent damage to the gear housing.
19 mm, Part No. 3822503 Liner Clamp

Assemble two cylinder liner clamps over the No. 1 cylinder
bore.
Tighten the cylinder liner clamps.
Position two flat washers on the piston so they will contact the
cylinder liner clamps.
Rotate the crankshaft clockwise until the washers on the piston

contact the cylinder liner clamps.
Mark the vibration damper adjacent to the pointer.
Rotate the crankshaft in the opposite direction until the washers

on the piston contact the cylinder liner clamps.
Mark the vibration damper adjacent to the pointer.
Measure the distance and mark the vibration damper at

one-half the distance between the two pointer marks. This is
the TDC mark. @I
19 mm
Remove the cylinder liner clamps and washers. Rotate the
crankshaft in the direction of rotation until the oointer aligns
with the TDC mark.
0a3
Look through the back side of the gear housing for the
timing pin hole in the camshaft gear. If the hole is not
visible, rotate the crankshaft one complete revolution.
Lubricate the o-ring with clean 15W-40 engine oil and install
into the groove of the timing pin.
Install the timing pin assembly.
itipimb
T-25 Torx””
Push the timing pin into the hole in the camshaft gear to align
the housing.
Hold the timing pin in while tightening the timing pin assembly
Torxm screws.
Check the timing pin to be sure it did not slip out of the
camshaft gear hole when the timing pin assembly screws were
tightened.
it900vc
13 mm, 18 mm
Caution: To prevent damage to the pin and gear, be sure to
disengage the timing pin before rotating the crankshaft.
Remove the vibration damper and wire pointer.
Flywheel Housing - Installation

Dry Clutch Application
Install the two dowel pins into the back of the cylinder block.
Drive the dowels in until they are against the bottom of the
bore.
fh9Dihe
Install two M12X1.75XlOO mm guide pins into the cylinder block

to help support and align the flywheel housing during
installation.
NOTE: Dry clutch applications require a sealing ring on the
rear seal housing. Install the sealing ring in the machined
surface of the rear seal housing and lubricate with Lubriplatem
105.
0a!3
Visually inspect the rear face of the cylinder block and
flywheel housing mounting surface for cleanliness and raised
nicks or burrs.
Install the flywheel housing. Be sure the flywheel housing is qb

positioned onto the alignment dowels and guide pins. Qj
0@3
NOTE: Be sure the sealing ring is not damaged during
installation.
Remove the two Ml 2X1.75X100 mm guide pins.
15 mm
Install and tighten the flywheel housing mounting capscrews •I
using the pattern shown in the chart.
Flywheel Housing Bore - Concentricity Checking

Part No. ST-1325 Dial Gauge Attachment
Attach a dial indicator to the crankshaft. The dial indicator
can be mounted by any method that holds the extension bar
Eil
of the indicator rigid so it does not sag. If the bar sags or
the indicator slips, the readings obtained will not be
accurate.
Position the indicator in the 6:00 o’clock position and zero
the gauge.

Slowly rotate the crankshaft. Record the readings obtained at
the 9:00 o’clock, 12:00 o’clock, and 3:00 o’clock positions as
[a], [b], and [c] in the concentricity work sheet. Check zero at
the 6:00 o’clock position again.
The values for [a], [b], and [c] could be positive or negative.
Refer to the accompanying figure to determine the correct sign
when recording these values.
Rotate the crankshaft until the dial indicator is at the 12:00

o’clock position and zero the gauge.
NOTE: Do not force the crankshaft beyond the point where the
bearing clearance has been removed. Do not pry against the
flywheel housing. These actions could cause false bearing
clearance readings.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as [d] in the concentricity work sheet.
This is the vertical bearing clearance adjustment and will always
be positive.
Use the concentricity work sheet to determine the values for

Concentricity Worksheet the ‘total vertical’ and ‘total horizontal’ values.
The ‘total horizontal’ is equal to the 9:00 o’clock reading, [a],
minus the 3:00 o’clock reading [cl.
The ‘total vertical’ is equal to the 12:00 o’clock reading [b],
plus the bearing clearance [d].
Example:
6:00 o’clock = ref = 0.000 mm [O.OOOin].
9:00 o’clock = [a] = 0.102 mm [0.004 in].
12:00 o’clock = [b] = 0.076 mm [0.003 in.]
3:00 o’clock = [c] = -0.051 mm [-0.002 in.]
Using the work sheet and the numbers from the example, the
‘total horizontal’ value = 0.152 mm [O.OOSin.] and the ‘total
vertical’ value = 0.127 mm [0.005 in.]
Mark the ‘total horizontal’ value on the horizontal side of the
chart and the ‘total vertical’ on the vertical side of the chart.
Use a straight edge to find the intersection point of the ‘total
horizontal’ and ‘total vertical’ values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Use the ‘total horizontal’ and ‘total vertical’ values from the
previous example, the intersection point falls within the shaded
area. Therefore, the flywheel housing concentricity is within
specification.
If the intersection point fails outside the shaded area, the ring
dowels must be removed and the housing repositioned.
The ring dowels are not required to maintain concentricity of
the housing. The clamping force of the capscrews holds the
flywheel housing in position.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Check the concentricity again by following the above
procedure.
Use the pattern shown in the chart to install and tighten the
mounting flywheel housing capscrews.
Torque Value: 60 Nom 145 ft-lb]
Wet Clutch Application

Perform all the steps in the procedure for dry clutch @@h
installation in addition to the following:
@
Coat the flywheel housing drain plug with pipe sealant and @/
install in the hole in the bottom of the flywheel housing.
47
Tighten the drain plug.
Refer to the pipe plug torque values in Group 18 for different
plug sizes.
b-J
Pipe
Sealant
Install the plastic plug in the tachometer drive access hole.
fhSpxha
13 mm
Install the access plate and new access plate gasket.
Install the access plate capscrews and tighten.
Thoroughly clean the flywheel housing and cylinder block

mating surfaces. These surfaces must be clean and free of oil
or debris.
NOTE: The center capscrew holes on the flywheel housing

mounting pads are drilled through. Coat set screws with
Loctitem 277 and install into holes.
Set Screw Installation Depth

mm in
0.00 MIN 0.000
3.00 MAX 0.118
fh9pxhc
Apply a continuous bead of Three Bond Sealant around all

capscrew holes on the mounting surface of the flywheel
housing.
Coat the threads of the mounting capscrews with LoctiteTM

277.
Install and tighten the capscrews. Follow the same tightening @I!&
4~
sequence used for the dry clutch application.
0@b
Flywheel - Installation
NOTE: Use a new pilot bearing when installing a new or
rebuilt clutch.
Use a mandrel and hammer to remove the pilot bearing.
Use a Scotch-Brite@ 7448 cleaning pad, or equivalent,
clean the pilot bore.
Use a mandrel and hammer to install the pilot bearing.

NOTE: The pilot bearing must be installed even with the pilot
bore surface.
Refer to Group 16 for flywheel ring gear replacement.
install two M12X1.25X90 mm guide pins into the crankshaft

flange 180 degrees apart.
NOTE: If a clutch is used in the equipment, the threads in the
clutch pressure plate mounting capscrew holes can be metric
or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size and install two
“T-handles” into the flywheel at points (1) and (2).
Visually inspect the rear face of the crankshaft and flywheel

mounting flange for cleanliness and raised nicks or burrs.
component.
Install the flywheel on the guide pins.
Lubricate the threads of the flywheel capscrews and the surface

of the washers with clean 15W-40 engine oil.
Install the six flywheel capscrews.

Remove the “T-handles” and guide pins.
Install the remaining flywheel capscrews into the holes from
which the guide pins were removed.
19 mm Socket, Torque Wrench, Part No. 3377371 Engine

Barring Tool
RI
Hold the crankshaft when tightening the flywheel capscrews.
Tighten the flywheel capscrews in the pattern as illustrated.
Torque Value: 137 Nom [lo1 ft-lb]
Flywheel Bore Runout Measurement

Use the dial indicator gauge (l), Part No. 3376050, or its
equivalent and dial gauge attachment (2) Part No. ST-1325,
to inspect the flywheel bore (3) and the surface (4) runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside
diameter of the flywheel bore, and set the dial indicator at
zero.
Use the engine barring tool, Part No. 3377371, to rotate the
crankshaft one complete revolution (360 degrees).
NOTE: The total indicator reading (TIR) must not exceed
0.127 mm [0.0050-inch].
NOTE: If the TIR is greater than the specification, do the

following:
l Remove the flywheel.
Engine Assembly (o-02) Engine Disassembly and Assemlby - Group 00
0@
l Inspect the flywheel mounting surface for dirt or
damage.
0
l Inspect the crankshaft for dirt or damage.
6B
l Install the flywheel, and inspect the flywheel bore

runout again.
fw9OOhe
l Replace the flywheel if the flywheel bore runout does

not meet specifications.
Flywheel Face Runout Measurement

Install the contact tip of the indicator against the flywheel
face, as close to the outside diameter as possible, to inspect
the face (1) runout.
NOTE: Push the flywheel forward to remove the crankshaft
end clearance. Adjust the dial on the indicator until the
needle points to zero.
Use the engine barring tool, Part No. 3377371, to rotate the
crankshaft one complete revolution. Measure the flywheel
runout at four equal points on the flywheel.
NOTE: The flywheel must be pushed toward the front of the
engine to remove the crankshaft end clearance each time a
point is measured.
The total indicator reading (TIR) must not exceed the

following specifications:
Flywheel Maximum (TIR)

Radius (A) of Flywheel Face
mm in mm in
203 8 0.203 0.008
254 10 0.254 0.010
305 12 0.305 0.012
356 14 0.356 0.014
406 16 0.406 fw900id
0.016
If the flywheel face runout is not within specifications, remove

the flywheel. Check for nicks, burrs, or foreign material
between the flywheel mounting surface and the crankshaft
flange.
Starting Motor - Installation

Wet Housing
Apply a coat of Three Bond Sealant to the starter mounting
surface and both sides of the spacer and starting motor gasket,
if equipped.
12 mm
go$ the starting motor capscrews with Loctitem pipe sealant
Install the starting motor. Tighten the starting motor capscrews.

Starting motor capscrews that are precoated with Vibra-Seal
require a lower torque.
Coolant Heater - Installation

Clean the expansion plug bore thoroughly. Make sure there
are no burrs or sharp edges that could cut the o-ring during
installation.
Lubricate the new heater o-ring with clean 15W-40 engine oil.
The coolant heater locking channel T-Bar should be loosened

to the end of the bolt.
Hook the element and one leg of the channel T-Bar into the @
hole as illustrated. 4@
Hook the other leg of the channel in the hole and push the @A
heater into the hole as far as possible by hand. 4W
Plastic Hammer, 4 mm Hex Wrench

If necessary, use a plastic hammer to tap the heater into the
bore until the flange contacts the block. Make sure the o-ring
is not damaged during installation.
NOTE: Do not use the screw to pull the heater into position,
this could damage the threads.
NOTE: The cable insertion socket should be oriented to the
9:00 o’clock position.
Tighten the retaining capscrew.

Insert the power cord into the socket, being careful to align the
pins with the sockets of the power cord. Tighten the retaining
nut by hand.
Do not apply power until the cooling system is filled.
Lubricating Oil Cooler - Installation

Refer to Group 07 for oil cooler assembly and rebuild
instructions.
Install two M8X1.25X80 guide pins into the cylinder block.
Assemble the cooler gasket, oil cooler, and oil cooler cover
gasket together over the guide pins.
If a new element is being installed, be sure to remove the
shipping plugs.
Install nine capscrews.
lc900hz
10 mm
Remove the two guide pins and install the remaining two
capscrews.
Tighten all the oil cooler and filter head capscrews.
Lubricating Oil Filter - Installation

Apply a light film of clean 15W-40 engine oil to the gasket
sealing surface before installing the filter.
NOTE: The filter must be installed within 15 minutes from the
q
&
4
time oil was applied to the rubber seal.

Fill the oil filter with clean 15W-40 engine oil.
Caution: Mechanical over-tightening may

threads or damage the filter element seal.
distort
Install the filter as specified by the filter manufacturer.

the
A
Cylinder Head - Installation

The cylinder block and head must be clean and dry. \
NOTE: The maximum allowable piston protrusion above the u
top of the block with a standard gasket is 0.40 mm [0.016
inch]. If the piston protrusion is greater than specified, refer @@
to Group 01 for information pertaining to thicker head
gaskets.
Make sure the gasket is correctly aligned with the holes
in the cylinder block.
Position the gasket onto the dowels.
The component weighs 23 kg [SO lb] or more. To avoid

component.
A
Caution: Do not drop the cylinder head on the cylinder
head gasket. The gasket material will be damaged.
0a!3
Carefully install the cylinder head onto the gasket and
cylinder block. Make sure the cylinder head is installed
onto the dowels in the cylinder block.
Use clean 15W-40 engine oil to coat the cylinder head

capscrew threads and underneath the head flange.
Do not install the capscrews with painted head in the center
row that will be covered by the valve cover.
Allow the excess oil to drain from the capscrew threads before
installation.
Install the capscrews into the cylinder head.

NOTE: Be sure to install the six capscrews in the holes
underneath the injectors.
NOTE: The top of the cylinder head capscrew is identified with

an angle marking. The cylinder head capscrews must be
tightened by using the three-step “torque plus angle” method,
described as follows:
1. Follow the numbered sequence and tighten all capscrews:

Torque Value: (Step One) 70 Nom 152 ft-lb]
Follow the numbered sequence and check the torque on all
capscrews again.
v Front
2. Follow the numbered sequence and tighten only the

fourteen long capscrews:
Torque Value: (Step Two) 145 Nom [105 ft-lb]
Follow the numbered sequence and check the torque on all
long capscrews again.
3. Torque Value: (Step Three)

Follow the numbered sequence and turn all the capscrews
90 degrees as indicated on the capscrew head.
knScsva
To accurately turn the capscrew to the desired angle, a small

“dot” and a “window” are marked on the capscrew head.
Window
knscsvb
Mark the cylinder head adjacent to the dot on the capscrew

head. This mark will serve as an indexing aid.
Rotate the capscrew until the mark that has been made on the
cylinder head falls into the “window” on the capscrew head.
Service Tip: Use a permanent marker to mark the socket

corresponding to one of the flats of the socket hex.
After the torque has been completed, mark the cylinder head
at the location of the dot.
Position the socket on the capscrew such that the mark on the
socket is at the same point as the window on the capscrew.
Turn the socket until the mark of the socket aligns with the
mark on the cylinder head.
Push Rod - Installation

Check the push rods for straightness.
pr9OOs.b
Install the push rods into the sockets of the valve tappets
from which they were removed.
Lubricate the push rod sockets and valve stems with clean
15W-40 engine oil.
u
4
Rocker Lever and Shaft - Assembly

Install the adjusting screw and locknut.
rhSOOfc
Install a retaining ring, thrust washer and wavy spring washer
rh9OOaa
Lubricate the shaft with clean 15W-40 engine oil.
rh9shwa
Position the levers on the rocker shaft.
rh9OOab
Install the remaining wavy spring washer, thrust washer and

retaining ring as illustrated.
rh9OOac
Compress the wavy spring washers and install the bottom @A

half of the pedestal as illustrated.
@
rh9OOad
Rocker Lever Assembly - Installation

Make sure the rocker
completely backed out.
lever adjusting screws are
0
@
rh9OOda
Install the supports and rocker lever assemblies over the OQn
rOGket’ lever oil manifold.
@
Make sure the dowels in the oedestals
. are installed into _
the dowel bores.
Use clean 15W-40 engine oil to lubricate the threads and

under the heads of the pedestal capscrews.
Install the retaining clamps and capscrews.
10 mm
RI Caution: To prevent damage to the rocker lever or push
rod, make sure the adjusting screw ball is positioned in the
socket of the push rods when tightening.
A
Tighten the retaining clamp capscrews.
0@h Torque Value: 55 Nom [41 ft-lb]
Valve Clearance - Adjustment
RI l/2 Inch Drive, Part No. 3377371 Engine Barring Tool

Locate top dead center (TDC) for cylinder No. 1 by rotating the
crankshaft slowly while pressing on the engine timing pin.
When the pin engages the hole in the camshaft gear, cylinder
No. 1 is at (TDC) on the compression stroke.
A Caution: To prevent damage to the timing pin, be sure to

disengage the pin after locating top dead center.
Feeler Gauge
Adjust the valves with engine cold (below 60°C [140” F]).
The clearance is correct when slight resistance is felt as the
feeler gauge is moved between the valve stem and rocker
Valve Clearance Specifications

mm in
0.30 Intake 0.012
0.61 Exhaust 0.024
Valve Arrangement
Beginning at the front of the cylinder head, the first valve is
intake, the second one is exhaust. The same orientation is
used for all cylinders.
IE IE IE IE IE IE
1 2 3 4 5 6
0 Front
14 mm, Flat Blade Screwdriver

Locate top dead center (TDC) for cylinder No. 1.
Adjust the valves indicated for Chart A.
RI
Tighten the locknut. CB
0%
Torque Value: 24 N*m [18 ft-lb]
Check the valve clearance again.
Mark the end of the crankshaft or flywheel, Rotate the

crankshaft 360 degrees.
Caution: Be sure the timing pin is disengaged.
A
14 mm, Flat Blade Screwdriver

Adjust the valves indicated for Chart B.
Tighten the locknut.
Chat-t B Torque Value: 24 Nom [18 ft-lb]

Cylinder 1 2 3 4 5 6 Check the valve clearance again.
Intake X x x
Exhaust X X X
Valve Cover - Installation

Install the rubber seal into the groove in the valve cover. Start
the installation at the overlap area shown in the illustration. Do
not stretch the rubber seal. If the seal has more overlap than
shown in this illustration, trim the excess to provide the proper
overlap.
vc900sb
Install new sealing o-rings on the valve cover capscrews.

NOTE: Engines equipped with wastegate turbochargers must
have a studded capscrew installed in the third hole from the
front. This is for the wastegate actuator hose clamp.
15 mm
Install the valve cover capscrews and tighten in the sequence
shown.
Crankcase Breather Tube - Installation

13 mm, 18 mm
Install the breather tube and hose clamps. Tighten the
0@h
capscrews for the breather tube support brackets.
Torque Value:
A = 24 Nom [18 ft-lb]
B = 43 Nom [32 ft-lb]
Injector - Installation
Lubricate the sealing lips of the sleeve with anti-seize
04
compound. Assemble the injector, sealing sleeve, a new
copper sealing washer and the holddown clamp.
Use only one washer.
Service Tip: A light coat of clean 15W-40 engine oil between
the washer and injector will aid in holding the washer in
place during installation.
Install the injector assembly into the injector bore. The @@A
injector leak-off connection must be toward the valve cover.
G@
13 mm
Install the holddown capscrew.
Fuel Drain Manifold - Installation

10 mm
Install the fuel drain manifold and new copper sealing washer
as illustrated.
NOTE: The banjo connector seal (Siamese washer) must be
installed as illustrated.
10 mm
Install new sealing washers and connect the drain manifold.to
the fuel filter head.
Torque Value:
Filter Head Banjo 15 Nom [ll ft-lb]
Injector Banjo 9 Nom [80 in-lb]
ftQseha
Engine Lifting Bracket - Installation

18 mm
Install the front bracket onto the front exhaust side of the
cylinder head.
Install the rear bracket on the rear of the cylinder head. Tighten
the capscrews.
I\ I I \ IaQOOha
Intake Manifold Cover - Installation

Install the manifold cover, gasket and capscrews (charge air
cooled engines). Do Not install capscrews in the holes used
to secure the high pressure fuel line support brackets.
Aftercooler - Installation
Install the aftercooler, gasket and capscrews, if equipped. Do @$
not install capscrews in the holes used to secure the high @
0%
pressure fuel line support brackets.
Install the coolant supply tube (1) and coolant return tube w
(2). Tighten the hose clamps.
Torque Value: 6 N*m [53 in-lb]
Exhaust Manifold - Installation

Assemble the exhaust manifold capscrews, new lock plates,
and gaskets on the manifold. Apply a thin coating of nickel
based, high temperature, anti-seize compound to the
capscrew threads.
NOTE: The exhaust manifold gasket can be installed in either
direction.
The tabs in the holes of the gasket are designed to hold the
gasket in place during installation.
V
xm900ht
15 mm
Install the exhaust manifold and gaskets. Follow the
sequence shown and tighten the capscrews.
0\
After the capscrews are tightened to the correct torque value,
bend over the lockplates to prevent the capscrews from r
loosening.
\ ‘I xm9OOha
Turbocharger - Installation
Use precoated turbocharger mounting studs or apply a thin
coating of nickel based, high temperature, anti-seize compound
to the coarse threads of the stud.
Use two nuts locked together to install the studs.

tb9OOwd
15 mm
Install the turbocharger mounting gasket with the raised bead
facing the exhaust manifold.
Install the turbocharger.
13 mm
NOTE: It may be necessary to orient the turbocharger center
bearing housing and/or compressor outlet.
To orient the center bearing housing, bend the lockplates, lf
equipped, and loosen the turbine housing capscrews and
position the bearing housing.
Turbocharger Oil Drain Tube - Installation

Apply a thin coat of LoctiteTM 277 around the flanged end of
the lower drain tube. Use a tube driver and hammer to drive
the tube into the bore until the flange contacts the cylinder
block. Make sure the end of the tube is in the 12:00 o’clock
position.
NOTE: If a tube driver is not available, a 22 mm open end
wrench can be used as illustrated.
13 mm
Install the hose and clamps on the turbocharger drain tube
loosely. Install the drain tube and gasket on the
turbocharger. Tighten the oil drain tube capscrews.
Torque Value: 24 Nom 118 ft-lb1
Position the turbocharger drain hose to connect the drain OQn

tube, tighten the clamps.
439
Torqire Value: 5 Nom [44 in-lb]
13 mm, Punch, Hammer

If loosened, tighten the turbine housing capscrews. Bend the
lockplates onto the flats to prevent loosening.
7/16 inch, 10 mm
Orientation of the compressor outlet requires the compressor
housing V-band clamp to be loosened.
If required, loosen the compressor housing and position the
housing to align with the air crossover tube.
When orienting the compressor outlet on turbochargers with
wastegate actuators, do not force the movement of the
housing. This will damage the actuator bracket and cause
internal damage to the turbocharger.
7/16 inch, Plastic Hammer

Loosen the two capscrews that secure the actuator bracket
brace to the V-band clamp. After orientation, first tighten the
V-band clamp nut, tap around the V-band clamp with a plastic
hammer, then tighten the two capscrews on the brace.
Torque Value:
V-Band Clamp Nut 8 Nom [ 71 in-lb]
Actuator Bracket Brace Capscrews 13 Nom 1115 in-lb]
NOTE: New or rebuilt turbochargers must be prelubricated

before start-up.
Pour 50 to 60 cc [2 to 3 oz.] of clean 15W-40 engine oil into
the oil inlet fitting on top of the turbocharger while spinning the
turbocharger impeller to distribute the oil in the bearing.
Turbocharger Oil Supply Hose - Installation

16 mm Crowfoot, 19 mm Socket
Apply vegetable oil to the o-rings of the adapter fittings.
Install the fittings into the oil filter head and top of the
turbocharger bearing housing.
Tighten the fittings.
Torque Value: 24 Nom [18 h-lb]
Install the oil supply line.
Turbocharger Exhaust Outlet Connection

Installation
Install the exhaust outlet connection.
NOTE: Do not tighten the two mounting capscrews until the
band clamp has been tightened.
Torque Value:
Band Clamp 8 N*m [71 in-lb]
Capscrews 48 N*m [32 ft-lb]
Air Crossover Tube - Installation

Screwdriver
Install the air crossover tube and clamps and tighten.
@
Be sure there is a minimum of 9.5 mm [0.375 inch] between
the compressor outlet and the crossover tube.
Thermostat and Housing - Installation

Install two thermostats into the bores as illustrated.
Refer to Group 07 for thermostat testing procedures.
Install a new gasket and the thermostat housing. Install two @A

capscrews and do not tighten until after the coolant outlet 4~
connection is installed.
Coolant Outlet Connection - Installation

10 mm
Install a new gasket and the coolant outlet connection.
Tighten the thermostat housing and coolant connection
capscrews.
Coolant Filter - Installation
q
4 Apply a light film of clean 15W-40 engine oil to the gasket
sealing surface of the coolant filter.
Caution: Mechanical over-tightening may distort the threads
A or damage the filter head.
Install the coolant filter as specified by the filter manufacturer.
e
0% +I
Coolant Vent Fitting - Installation
RI 9/16 inch
Coat the threads with pipe sealant with Teflon and install the
l/8 inch coolant vent fitting.
3+*
‘>% Tighten and orient the fiiing
12:00 o’clock position.
so the petcock bore is at the
(K
0
Coolant Vent Petcock - Installation

9/16 inch
Coat the threads with pipe sealant with Teflon and install the
vent petcock.
Engine Assembly (O-02)
Engine Disassembly and Assembly - Group 00 Page O-103
614 Series
Coolant Vent Tube - Installation

7/16 inch
Coat the threads with Teflon and install the
tube. Tighten the fitting.
Coolant Inlet Connection - Installation

ln;nb the new coolant inlet connection and tighten the

The final positioning of the inlet connection may need to be
made after installation of the engine in the vehicle.
Alternator Mounting Bracket - Installation

13 mm
RI
Assemble the alternator bracket to the thermostat housing.
Alternator - Installation
Position the alternator on the bracket and install the
mounting capscrews.
The capscrews should be installed with the nuts facing
toward the inside of the bracket.
Do not tighten at this time.
Alternator Brace - Installation

13 mm
Install the capscrew into the alternator brace and water pump.
Finger tighten the capscrew.
Caution: Make sure the alternator brace is positioned

properly for correct belt alignment.
Connect the alternator brace to the alternator. Finger tighten
the capscrew.
Tighten the water pump mounting capscrew.

15 mm, 18 mm, 19 mm
Tighten the alternator mounting capscrew.
Torque Value:
A = 43 Nom [32 ft-lb]
B = 24 Nom [18 ft-lb]
C = 80 Nom [59 ft-lb]
Belt Tensioner Bracket - Installation

5 mm Hex Wrench
Install the tensioner bracket onto the front of the thermostat
housing.
Tighten the hex head screws.
Torque Value: 24 Nom [18 f&lb]
Belt Tensioner - Installation

15 mm
Position the belt tensioner onto the bracket and secure it
with the capscrew. Make sure the tensioner locating tab is
positioned in the unthreaded hole of the tensioner bracket.
0%
Engine - Removal from the Rebuild Stand

Part No. 3622512 Engine Lifting Fixture
Warning: To prevent personal injury, the engine lifting
equipment must be designed to safely lift the engine as
Eil
an assembly. The dry weight of the engine with standard
accessories is 606 kg [1335 lb]. A
Use a properly rated hoist and engine lifting fixture such as
Part No. 3822512, attached to the engine mounted lifting a
@@
brackets to lift the engine.
Warning: The engine can move or drop a small distance
as it is being removed from the rebuild stand. Use
extreme care to prevent personal injury. A
Use the hoist and lifting fixture to apply lifting tension to the
engine.
Remove the six capscrews that hold the engine to the
adapter plate.
Use the hoist to lower the engine to suitable engine support
stands or a shipping skid.
Remove the hoist and lifting fixture from the engine.
Fan Hub Assembly - Installation

10 mm
Install the fan hub. Be sure the fan hub shaft assembly turns
freely. Tighten the capscrews.
Torque Value: 24 Nom (18 ft-lb]
Fuel Injection Pump - Installation

Loctitem is used to help retain the injection pump mounting
studs.
Apply LoctiteTM 242 to the threads of the studs.
13 mm
Use two nuts locked together as illustrated to install the studs.
fp9OOht

Make sure the piston in cylinder No. 1 is at TDC.
NOTE: Rotate the crankshaft only in the direction of rotation.
The fuel injection pump also has a timing pin (l), located in
the governor housing, to position the pump shaft to
correspond with TDC for cylinder No. 1. After the pump is
installed, the timing pin must be reversed and stored in the
governor housing (2).
24 mm
Remove the access plug.
Remove the timing pin.
fs9pima
0a!3J
I-
If the timing tooth is not aligned with the timing pin hole, r
rotate the pump shaft until the timing tooth aligns.

0
Reverse the position of the pin so the slot of the pin will fii
over the timing tooth in the fuel injection pump.
Install and secure the tming pin with the access plug.
Make sure the o-ring seals for the fill orifice (A) and pilot
(B) are correctly installed and are not damaged.
Lubricate the mounting flange with clean engine oil.
NOTE: The fuel pump drive gear inside diameter and the shaft
outside diameter must be clean and dry before installing the
gear.
NOTE: The drive gear does not require a Woodruff key. If

using a new replacement pump, remove and discard the key.
Position the pump flange onto the mounting studs.
15 mm and 13 mm, Part No. 3823956 Fuel Pump Mounting

Tool Kit
Install the mounting nuts.
Torque Value:
Mounting nuts 44 Nom [32 ft-lb]
Support bracket 32 N*m [24 ft-lb]
Page O-109
614 Series

27 mm (PESGMW Fuel Injection Pump) •II
Caution: To prevent damage to the timing pins, do not
exceed the torque value given. This is not the final torque
A
value for the retaining nut. %
Install the fuel pump drive gear, retaining nut and washer. @@
Initial Torque Value: 12 Nom 1106 in-lb]
Disengage the engine timing pin.
24 mm
Remove the fuel pump timing pin plug. Reverse the position
of the pin and install the pin, plug and sealing washer.
0@a

27 mm (PESGMW Fuel Injection Pump)
Tighten the fuel injection pump drive gear nut.
Pump Model Torque Value:
PESGA 92 Nom [ 68 ft-lb]
PESGMW 104 Nom [ 77 ft-lb]
PESGP 165 Nom [122 ft-lb]
Page O-l 10 614 Series
Caution: The governor housing must be prelubricated

Oil Fill before engine operation. Failure to do so will result in
premature governor weight wear.
10 mm hex drive
Remove the access plug.
Add the following quantity of clean 15W-40 engine oil:
l RSV 450 ml [0.43 qt.]
l RQV 750 ml [0.71 qt.]
l RQVK 750 ml IO.71 qt.]
Install the access plug.
Position an indicator on a tooth of the injection pump drive

gear.
Note the total indicator travel as injection pump drive gear

backlash.
Hold the adjoining camshaft gear from moving when checking
backlash or the readings will be the total of both gears.
Fuel Pump Drive Gear Backlash Limit

mm in
0.152 MIN 0.006
0.254 MAX 0.010
Fuel Injection Pump Supply Line - Installation

17 mm and 19 mm
Use new sealing washers and install the injection pump supply
line.
Tighten the banjo fittings.
A = 32 Nom [24 ft-lb]
B = 25 Nom [18 ft-lb]
Install the fuel return line.
614 Series Page 0-t 11
Fuel Filter Head - Installation

If the optional dual filter is to be used, install the adapter and @A
o-ring. G!W
I ff9adhs
Install the o-ring in the dual filter head. Lubricate the o-ring @
and the center hole with clean 15W-40 engine oil.
W
24 mm
Install the dual filter head.
Tighten the nut.
Fuel Filter - Installation

Temporarily install the fuel filter(s).
When the engine is ready to be put into service, fill the

filter(s) with clean No. 2 diesel fuel and tighten l/2 turn
after the lubricated gasket contacts the filter head.
ff9etha
Fuel Lines, High Pressure - Installation

10 and 17 mm (PESGA and PESGMW Fuel Injection Pump)
10 and 19 mm (PESGP Fuel Injection Pump)
Loosen the vibration isolator capscrews so the fuel lines can be
easily moved.
NOTE: To prevent breakage to the fuel lines, they must be
connected to the iniector and fuel injection pump in a “free
state” without forcing the connectng nuts. Since the fuel lines
are properly sized for specific application, bending should not
be necessary.
Caution: If removed, install the support clamp in the original

position and make sure the lines do not contact each other
or another component.
Install the high pressure fuel lines in the reverse order of
removal.
Tighten all high pressure fuel line fittings and mounting

hardware.
Torque Value:
1. Line Fittings 30 Nom [22 ft-lb]
2. Support Bracket Capscrews 24 Nom [18 ft-lb]
3. Vibration Isolator Capscrews 6 Nom [53 in-lb]
AFC Tube - Installation

17 mm, 13 mm
Install the AFC tube.
Torque Value:
Threaded Fitting 8 Nom 171 in-lb]
Seal, Front Crankshaft - Installation

Use the installation tool from the seal replacement kii to @J?J
install the seal to the correct depth into the seal bore of the @
gear cover.
Leather Mallet
To prevent damage to the seal, place a block of wood over •l
the installation tool. Support the back side of the gear cover
around the seal area with a block of wood. Hit the block
corresponding to the middle of the seal until the seal carrier
is even with the outside of the gear cover flange.
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Wear Sleeve, Front Crankshaft - Installation
0@3
NOTE: Visually inspect the seal contact area of the
crankshaft for a wear groove. If the seal has worn a groove
deep enough to be felt with a sharp object or fingernail, it
will be necessary to install a wear sleeve to prevent an oil
leak.
NOTE: The oil seal used with the wear sleeve has a larger
inside diameter than the standard seal. The two seals are not
interchangeable. Refer to the appropriate Parts Manual for
the correct part number.
Part No. 3823908 Crankshaft Front Wear Sleeve

Installation Tool
Use the driver to install the wear sleeve to the correct
position on the crankshaft. The kit consists of the following:
Ref. Description QtY.

No.
1 Driver 1
2 Spacer 2
3 Capscrew Ml 4X1 5X6Omm 2
ks9tolb
4 Hair Pin Cotter 2
Apply a thin coat of 15W-40 engine oil to the driver inside

diameter and capscrew threads.
Use crocus cloth or equivalent to remove rust and corrosion

deposits from the crankshaft flange.
Apply a thin coat of 15W-40 engine oil to the crankshaft flange.
Position the chamfered end of the wear sleeve onto the end of
the crankshaft.
Position the counterbore end of the driver onto the wear

sleeve.
Install two capscrews (without spacers or hair pin totters)

through the driver and into the crankshaft capscrew holes.
WEAR
Align the wear sleeve and driver perpendicular with the
crankshaft. Tighten the capscrews “finger tight”.
Alternately tighten the capscrews until the sleeve is installed

to a depth of approximately 16 mm [0.625 inch].
NOTE: To prevent damage to the wear sleeve, do not
exceed l/2 revolution of each capscrew.
Approximate torque value: 20 Nom [15 ft-lb]
Remove the capscrews and install a spacer on each

capscrew. Install the two capscrews again.
Continue to alternately tighten the capscrews until

of the driver contacts the end of the crankshaft.
Remove the driver. Use the hair pin totters to secure the
capscrews and spacers to the tool during storage.
Gear Cover - Installation

Caution: The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to prevent seal
leaks.
Thoroughly clean and dry the front seal area of the crankshaft.
Install the seal tool pilot from the service seal replacement kit
onto the nose of the crankshaft.
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Use two M8X1.25X70 mm guide pins to aid in alignment of the

gasket. Apply a coat of Three Bond Sealant to both sides of
the gasket.
Install the gasket and gear cover over the pilot.
NOTE: The seal will align the cover at the seal bore.
Install the capscrews.
10 mm
Tighten the gear cover capscrews.
/
00
iii!!3
Remove the seal tool pilot from the nose of the crankshaft.
00
@
00
_/ ti
--
0 0
0
0
I I 1
Install the crankshaft oil seal dust shield, if used, as follows:

l Push the dust shield (1) onto the crankshaft with the
part number facing out away from the engine.
l The dust shield should contact or be to within 4 mm
[0.15 inch] of the oil seal.
NOTE: Liquid soap will aid in installation.
Tachometer Drive - Installation

Install the tachometer drive and cable.
bp900ha
Vibration Damper - Installation

21 mm, Part No. 3377371 Engine Barring Tool
Install the vibration damper.
Use the engine barring tool to hold the engine from turning.
Install the fan hub pulley and secure with capscrews.

NOTE: It will be easier to tighten the capscrews after the belt
is installed.
Drive Belt - Installation

3/8 inch Square Drive
Lii the tensioner and install the drive belt.
Service Tip: If difficulty is experienced installing the drive belt
(the belt seems too short), position the belt over the fan hub
pulley first and then slide the belt over the water pump pulley
while holding the tensioner up.
13 mm
Tighten the fan hub pulley capscrews.
Engine Support, Front - Installation

15 mm
Install the front engine support.
Torque Value: 112 N l m [82 ft-lb]
Fuel Transfer Pump - Installation

10 mm
Apply a coating of Three Bond Sealant to the gasket.
Install the fuel transfer pump and new gasket.
Fuel Lines, Low Pressure - Installation

14 mm, 17 mm, 20 mm
Install the fuel line to the fuel transfer pump. Use two •l
wrenches to tighten the connection to the fuel transfer pump.
Fuel Pump Solenoid - Installation

8 mm
Install the solenoid and connect the wires.
Refer to Group 14 for engine testing.
Air Compressor - Installation

14 mm, 15 mm, 19 mm
Caution: Make sure the oil drain notch in the gear
A
housing is not blocked. The gasket must be installed with
the side marked “This Side Toward Gear Housing” facing
the gear housing.
Use a new gasket. Install the air compressor. Tighten the two @!A
mounting nuts. @W
0(K
NOTE: It is not necessary to time the air compressor on the cpS00ha
614 Series engine.
Install the mounting spacer to the engine block, use the 40 @A

mm long capscrews and tighten finger tight.
@
Install the air compressor brace (2) to the mounting spacer (1)
and adapter (3) on the air compressor using the 30 mm long
capscrews. Make sure the brace and spacer are aligned and
no parts are in a bind. Tighten evenly to the proper torque
value.
co9bkhb
9/16 inch
Install the oil supply line.
15116 inch
Caution: If rubber grommets are used on the coolant lines,
be sure they are installed carefully to prevent cuts or tears
to the grommets which will cause coolant leaks.
Install the coolant Ines.
Install and tighten the inlet and outlet connections.

Torque Value:
Inlet 5 N*m [48 in-lb]
*Outlet 24 Nom 118 ft-lb]
*l/2 NPT fitting in the compressor cylinder head.
NOTE: Torque value for the discharge line depends on the line
size and type.
Refer to the appropriate chassis Shop Manual for the correct
torque value.
Engine Accessories - Installation

Install the cover plate or any additional gear driven
accessories (hydraulic pump, freon compressor, etc.) as
needed.
NOTE: When gear driven accessories are installed, be sure
to install the correct support bracket.
gh9pIt
Cylinder Block - Group 01
614 Series Page l-1

Section Contents
Page
Camshaft Bore Expansion Plug Installation ........................................ 21
Camshaft Bushing Bore - Cleaning .............................................. 23
Camshaft Bushing - Installation ................................................ 23
Camshaft Bushing - Removal .................................................. 22
Camshaft - Cleaning and Inspection for Reuse ...................................... 50

Camshaft - Cleaning ........................................................
Camshaft Gear - Inspection ................................................... z:
Camshaft - Inspection ....................................................... 50
Camshaft Gear - Replacement ................................................. 54

Camshaft Gear - Cleaning .................................................... 54
Camshaft Gear - Inspection ...................................................
Camshaft Gear - Installation ................................................... z:
Camshaft Gear- Removal .................................................... 54
Connecting Rod Bearings - Cleaning and Inspection for Reuse ..........................

Connecting Rod Bearings - Cleaning ............................................. ::
Connecting Rod Bearings - Inspection ............................................ 39
Connecting Rod Bushing - Replacement .......................................... 45

Inspection ...............................................................
Installation .............................................................. :;
Machining.. ............................................................. 49
Removal ................................................................ 45
Connecting Rods - Bend and Twist Inspection ......................................

Connecting Rod Alignment - Inspection ........................................... z
Connecting Rod Twist - Inspection ..............................................
Fixture Calibration ......................................................... z
Connecting Rods - Cleaning and Inspection for Reuse ................................

Connecting Rods - Cleaning .................................................. 2
Connecting Rods - Inspection ................................................. 41
Crankshaft - Cleaning and Inspection for Reuse .....................................

Crankshaft - Cleaning ....................................................... f:
Crankshaft - Inspection ...................................................... 30
Crankshaft Gear - Replacement .................................................

Crankshaft Gear - Inspection .................................................. ;:
Crankshaft Gear - Installation ..................................................
Crankshaft Gear - Removal ................................................... E
General Information ........................................................ 33
Cylinder Block - Cleaning in a Hot Tank .......................................... 15
Cylinder Block - Cleaning with Solvent ........................................... 12
Cylinder Block - Disassembly .................................................. 10
Cylinder Block - Exploded View ................................................ 7
Cylinder Block - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

-Camshaft
Connectingkods 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1 :
Crankshaft . . . . . . . . . . . . . . . .._.._.._._..._._.._........_................... 9
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder Liner . . . . . . . . . . . . . . . . .._...._........._......_.._................. 9
Page l-2 614 Series
Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pistons.................................................................. 9
Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder Block - Inspection For Reuse ............................................ 16
Cylinder Block - Preparation for Cleaning ......................................... 10
Cylinder Block - Service Tools ................................................. 4
Cylinder Head Capscrews - Cleaning and Inspection for Reuse ..........................

Cleaning.. ..............................................................
Free Length - Measurement ...................................................
Inspection ...............................................................
Cylinder Liners - Cleaning and Inspection for Reuse .................................. 24

Cylinder Liners - Cleaning ....................................................
Cylinder Liners - Inspection ................................................... f;
Dowel Pins (Cylinder Head) - Removal ........................................... 11
Engine Dataplate - Replacement ................................................

Engine Dataplate - Installation .................................................
Engine Dataplate - Removal ...................................................
Engine Lifting Brackets - Cleaning and Inspection for Reuse ............................ 66
Expansion Plug - Installation ................................................... 19

Pipe Plug - Installation ...................................................... 20 .
Gear Cover - Cleaning and Inspection for Reuse ....................................

Gear Cover - Cleaning ...................................................... Ei
Gear Cover - Inspection ..................................................... 60
Gear Housing - Cleaning and Inspection for Reuse ...................................

Gear Housing - Cleaning ..................................................... z5
Gear Housing - Inspection .................................................... 57
Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse ...................
Cleaning.. .............................................................. ::
Inspection ............................................................... 39
Main Bearings - Cleaning and Inspection for Reuse ..................................

General Information ........................................................ ::
Main Bearings - Cleaning .................................................... 37
Main Bearings - Inspection ................................................... 37
Thrust Bearings - Inspection .................................................. 38
Pistons - Cleaning and Inspection for Reuse ....................................... 27

Piston Rings - Removal ......................................................
Pistons - Cleaning ......................................................... :5
Pistons - Inspection ........................................................ 28
Rear Cover - Cleaning and Inspection ............................................ 63

Cleaning ................................................................ 63
Inspection ............................................................... 64
Vibration Damper - Cleaning and Checking for Reuse ................................. 61

General Information ........................................................ 61
Rubber Element Vibration Damper - Inspection ......................................
Rubber Vibration Damper - Cleaning ............................................. :;
Viscous Vibration Damper - Cleaning ............................................. 62
Viscous Vibration Damper - Inspection ............................................ 62
Cylinder Block - Group 01 Cylinder Block - Service Tools
614 Series Page l-3
Cylinder Block - Service Tools
Tnnl Nn Tnnl
..r_.
lbacrintinn
‘~_....~“_..
Tnnl Ilhfldratinn
Measure connecting rod length, twist and bore alignment. Use

with Part No. 3823288, connecting rod checking mandrel kii.
Remove dowel pins.
Used when installing pipe plugs, cup plugs, etc. on the engine
Used to measure internal diameter bores from 78.5 mm [3.09

in] to 2.032 mm [8.0 in].
Inspect components for cracks.
Used to remove expansion plugs.

Cylinder Block - Service Tools Cylinder Block - Group 01
Page l-4 614 Series
Aid in removal and installation of crankshaft, flywheel and other

heavy components.
Used with all expansion plug drivers larger than 0.375 inch
Expansion Plug Driver
Install 1.00 inch expansion plug to specified depth. Used with

expansion plug driver handle, Part No. 3376795.
Install 0.375 inch expansion plug to specified depth.
Metric Thread Insert Kit
Repair damaged internal metric threads.
Piston Ring Expander
Used to install piston rings onto pistons without damaging or

distorting the rings.
Used with Part No. ST-561, connecting rod checking fixture, to

check length, twist and bore alignment.
Remove and install camshaft bushings.

Cylinder Block - Group 01 Cylinder Block - Service Tools
614 Series Page l-5
Install 0.8125 inch expansion plug to specified depth. Used

3823521 with expansion plug driver handle, Part No. 3376795.
Install 1.1875 inch expansion plug to specified depth. used

3823522 with expansion plug driver handle, Part No. 3376795.
Install 1.375 inch expansion plug to specified depth. Used with

3823523 expansion plug driver handle, Part No. 3376795.
Used to install 2.250 inch expansion plug to specified depth.

3823524
Connecting Rod Pin Bushing Removal/installation Tool
Remove and install service bushing in the pin end of the con-
3823690 necting rod.
Capscrew Length Gauge
Used to measure capscrew free length.

3823921
Piston Ring Groove (Keystone Angle) Wear Gauge
Measure the wear of the intermediate piston ring groove key-

3823965 stone angle.
Piston Ring Groove (Keystone Angle) Wear Gauge
Measure the wear of the top piston ring groove keystone

3823966 angle.
Cylinder Block - Exploded View
Page 1-6 Cylinder Block - Group 01
614 Series
Cylinder Block - Exploded View
w --
61
57
Cylinder Block - Group 01 Cylinder Block - Exploded View
614 Series Page l-7
Ref. No. Description QW Ref. No. Description W

1 Block, Cylinder 1 38 Pin, Timing 1
2 Cap, Main Bearing 7 39 Ring, Retaining 1
3 Screw, Hex Head Cap (Flange) 14 40 Screw, Round Head Cap 2
4 Bushing, Camshaft 7 41 Gasket, Gear Cover 1
5 Plug, Expansion 4 42 Cover, Gear 1
6 Plug, Expansion 4 43 Seal, Front Crankshaft 1
7 Plug, Expansion 1 44 Screw, Hex Head Cap (Flange) 17
a Plug, Expansion 1 45 Screw, Hex Head Cap (Flange) 6
9 Plug, Expansion 1 46 Cap, Front Cover 1
10 Plug, Expansion 1 47 Seal, Rectangular 1
11 Plug, Expansion 2 48 Screw, Hex Head Cap 1
12 Liner, Cylinder 6 49 Crankshaft 1
13 Plug, Pipe 5 50 Pin, Dowel 1
14 Plug, Pipe 6 51 Gear, Crankshaft 1
15 Draincock 1 52 Bearing, Main (Upper) 6
16 Plug, Pipe 1 53 Bearing, Flange (Thrust) 1
17 Pin, Dowel 4 54 Bearing, Main (Lower) 7
ia Pin, Dowel 2 55 Damper, Vibration 1
19 Nozzle, Piston Cooling 12 56 Screw, Hex Head 4
20 Plug, Pipe 1 57 Tube, Oil Gauge 1
21 Rod, Engine Connecting 1 58 Plug Expansion 2
22 Bolt, Connecting Rod 2 59 Filler Cap 1
23 Nut, Rectangular Hexagon 2 60 Tube, Oil Fill 1
24 Bushing 1 61 Plug, Expansion 1
25 Bearing, Connecting Rod 12 62 Plug, Pipe 1
26 Piston, Engine 6 63 Sealing Ring 6
27 Pin, Piston 6 64 Camshaft 1
28 Ring, Retaining 12 65 Gear, Camshaft 1
29 Ring, Piston (Top) 6 66 Support, Camshaft Thrust 1
30 Ring, Piston (Mid) 6 67 Screw, Hex Head Cap 2
31 Ring, Piston (Oil) 6 66 Wear Sleeve, Front Crankshaft 1
32 Gasket, Gear Housing 1 69 Wear Sleeve, Rear Crankshaft 1
33 Housing, Gear 1 70 Capscrew, Hex Head (Flange) a
34 Screw, Hex Head Cap (Flange) 4 71 Cover, Rear 1
35 Seal, Timing Housing 1 72 Gasket, Rear Cover 1
36 Housing, Timing Pin 1 73 Seal, Oil Rear Crankshaft 1
37 Seal, O-Ring 1 74 Seal, Rectangular 1
Cylinder Block - General Information Cylinder Block - Group 01
Page 1-8 614 Series
Cylinder Block - General Information
Camshaft
The profile of the camshaft lobes is the same for all 614 Series engines.
The camshaft end clearance is determined by the clearance between the camshaft and the thrust plate.
Camshafts that are damaged or worn on the fuel transfer pump or the valve lobes must be replaced. Komatsu Dresser
Company does not recommend grinding the camshaft lobes.
Crankshaft
The crankshaft is a balanced, forged steel, full fillet hardened unit with seven main bearing journals. The lower bearing
shells are all the same. All of the upper bearing shells are the same except for the No. 4 journal which has a flanged
upper bearing shell. The flanges on the bearing shell control the end thrust of the crankshaft.
Oversize main bearings and thrust bearings are available for service. Komatsu Dresser Company recommends
regrinding ALL of the main or the connecting rod journals when ONE requires regrinding.
Cylinder Block
The cylinder block has provisions for the oil cooler housing, thermostat seats, coolant bypass line, water pump volute,
oil pump housing, water pump inlet and replaceable cylinder liners.
Cylinder Liner
The cylinder liner is a replaceable mid-stop design. The liner seat area is located midway of the length of the liner. Coolant
sealing between the liner and block is provided by a press fit at the top and by a sealing ring at the mid-stop of the liner.
Oil Seals
All crankshaft seals on the 614 Series are the Teflon TMlay-down lip (scroll) type. The Teflonm laydown lip type seal does
not contain a spring on the back of the sealing lip. The sealing lip is a thin, stiff piece of Teflonm.
Teflonm seals must be dry before installation. Do not lubricate the seal lip or the shaft. After the first few revolutions of
the shaft, a thin film of TeflonTM is transferred from the seal lip to the shaft. If the shaft is not clean and dry, this transfer
will not occur and the seal will leak. There are service replacement wear sleeves available for both front and rear
crankshaft oil seals.
Pistons
The pistons have a cast aluminum body, with both high swirl and low swirl combustion bowls and three ring grooves.
The top two ring grooves have a ni-resist insert with a Keystone profile. The pistons for the different engine configurations
are similar in appearance, but are not interchangeable. Always check the part number to be sure the correct piston is
used during piston replacement.
Vibration Damper
The vibration damper controls the twisting or torsional vibration of the crankshaft. The vibration damper is engineered for
use on specific engine models, depending on the horsepower rating and engine speed.
It is not economical to repair a vibration damper in the field. Install a new or a rebuilt vibration damper if the inspection
indicates that a damper is defective.
Connecting Rods
The connecting rods have replaceable bronze bushings.

Cylinder Block - Group 01 Cylinder Block - Preparation for Cleaning (l-01)
614 Series Page l-9
Cylinder Block - Preparation for Cleaning

(l-01)
It is necessary to thoroughly clean the cylinder block if it is \
going to be reused. To properly clean the block, all pipe IJ
plugs and expansion plugs must be removed. It is also
recommended to remove the camshaft bushings.
Refer to Procedure l-09.
0a
Before beginning disassembly of the block, perform a visual
inspection to see if there is any damage that would prohibit
reuse.
Cylinder Block - Disassembly (I-02)

Remove the pipe plugs from the coolant passages.
Remove the pipe plugs from the oil passages.

c%
0
ck9pxmC
Dowel Pins (Cylinder Head) - Removal (l-03) Cylinder Block - Group 01
Page l-10 614 Series
Part No. 3375784, Light Duty Dent Puller, Drill Motor, 3 mm

RI [l/8 inch] Drill Bit
c%
Drill a 3 mm [l/8 inch] hole and use a slide hammer equipped
with a No. 10 sheet metal screw to remove expansion plugs.
Q
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Remove the expansion plugs from the oil passages.

CB
l
Remove the expansion plugs from the coolant passages.
Dowel Pins (Cylinder Head) - Removal

(I-03)
Use a dowel pin extractor, Part No. ST-l 134, or its equivalent.
Remove the two cylinder head dowel pins.
l Put the split collet (1) over the dowel pin.
l Slide the extractor collar (2) over the split collet.
l Use the slide hammer (3) to push the extractor collar
over the split collet tightly.
l Use the slide hammer to remove the dowel pin.
Cylinder Block - Cleaning with Solvent (l-04)
Page l-l1
614 Series
Cylinder Block - Cleaning with Solvent

(l-04)
Cleaning Brush
Use clean solvent and a brush to clean the main oil passage.
\
B
Cleaning Brush
Use clean solvent and a brush to clean the main bearing to
camshaft bore oil passage.
Cleaning Brush
Use clean solvent and a brush to clean the piston cooling
nozzle passages.
Cleaning Brush
Use clean solvent and a brush to clean the oil passage from I3.l
the camshaft bore to the rocker assemblies.
\
Ll
Cylinder Block - Cleaning with Solvent (I-04) Cylinder Block - Group 01
Cleaning Brush
Use clean solvent and a brush to clean the oil cooler oil
\
Ll
passages.
Thoroughly clean all gasket sealing surfaces.
Clean the cylinder block head deck with a Scotch-B&Q 7448

cleaning pad or equivalent and solvent.
\
q
Clean the top cylinder liner press surface (A) and the mid-stop
ledge (B) and (C) with a Scotch BriieQ 7448 cleaning pad or
equivalent and solvent.
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Cylinder Block - Group 01 Cylinder Block - Cleaning with Solvent (l-04)
Thoroughly clean all expansion plug bores with a Scotch

Brite@ 7448 cleaning pad, or equivalent, and solvent.
Inspect the coolant passages for rust or restriction. Use

bristle brushes to clean the coolant passages.
Warning:
injury.
Use protective measures to prevent personal
A
Build-up of deposits
engine overheating.
in the coolant passages can cause
\
q
NOTE: Excessive deposits may be cleaned in an acid tank,
but the camshaft bushings and piston cooling nozzles must
first be removed to prevent damage.
Warning: Use protective measures to prevent personal

injury. A
q
NOTE: The block may be cleaned in a hot tank using a soap
and water solution without removing the camshaft bushings. B
Cylinder Block - Cleaning in a Hot Tank (l-05) Cylinder Block - Group 01
Cylinder Block - Cleaning in a Hot Tank

(I-05)
component.
Use a hoist or hydraulic arm to move the cylinder block into
the cleaning tank.
Follow the instructions of the manufacturer of the cleaning tank
and the manufacturer of the cleaning solution.
ck9bde
NOTE: Komatus Dresser Company does not recommend any
specific cleaning solution.
A cleaning tank that will mix and filter the cleaning solution
gives the best results.
Remove the block from the cleaning tank.
Use a nylon bristle brush to clean the oil passages.
clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam or solvent to clean the cylinder block. Dry with
compressed air.
ck9bdq
Caution: Do not damage the machined gasket surfaces.

Use a gasket scraper to clean the cylinder block deck surface.
Use Scotch Brite@ 7448, or equivalent, and solvent to remove
any residual gasket material from the cylinder block gasket
surfaces.
Caution: When using compressed air to clean capscrew
holes, always wear safety glasses or a face shield to protect
the eyes. Personal injury can result. Be sure all of the water
and debris is removed from the capscrew holes and the oil
passages.
Use compressed air to dry the block.
NOTE: If the cylinder block is not going to be used

immediately, apply a coating of preservative oil to prevent rust.
Cover the block to prevent dirt from sticking to the oil.
Cylinder Block - Group 01 Cylinder Block - Inspection For Reuse (l-06)
614 Series Page l-15
Cylinder Block- Inspection For Reuse

(I-06)
NOTE: All measurements of the cylinder block must be made
when the block is positioned on a flat surface. If the block is
mounted on the engine stand, the measurements can be
incorrect because of distortion.
0e
Inspect all gasket surfaces.
Visually inspect for burrs or damage.
Use a medium grii hone or crocus cloth to remove burrs.
-
Straight Edge and Feeler Gauge

Visually inspect the cylinder block head deck for damage.
0QB
Check the cylinder block head deck for flatness between
each cylinder.
Cylinder Block Flatness Specification

mm in
0.075 End-to-End 0.003
0.075 Side-to-Side 0.003
Caution: Do not proceed with the repair if the cylinder

block head deck is damaged or not flat. A
NOTE: The cviinder block head deck can be resurfaced in a
machine shob and a thicker surface cylinder head gasket
installed to keep the piston-to-valve clearance the same.
The upper right corner of the rear face of the block must be
stamped with an “x” when the block is resurfaced to 0.25
mm [O.OlO inch]. A second “x” must be stamped beside the
first when the block is resurfaced to 0.50 mm [0.020 inch].
ck9bdga
Cylinder Block - inspection For Reuse (l-06) Cylinder Block - Group 01
Consult the 614 Series parts catalog for the correct gasket to
be used with resurfaced blocks to be sure of proper
piston-to-valve clearance.
NOTE: The gaskets are notched and color coded to aid in
identification. The standard gasket is red and does not have a
notch.
A= (Silver) Use where cylinder block head deck has been
resurfaced
0.25 mm [O.OlO in] (two notches)
kn9QaQ.3
B= (Blue) Use where cylinder block head deck has been
resurfaced
0.50 mm [0.020 in] (three notches)

Measure the upper press fit area of the cylinder liner bore.
Cylinder Liner Bore in Block (Press Fit Bore)

mm in
132.800 MIN 5.2323
132.990 MAX 5.2358
n Part No. 3375432, Crack Detection Kit

Caution: Clean all deposits and debris from sealing
surfaces A, B and C. Use Scotch Brite 7448@ or equivalent
and cleaning solvent to polish the surfaces. However, due
to the critical machined tolerances, care should be taken
not to remove any additional material.
Use a crack detection kit, Part No. 3375432, or its equivalent.
Check the counterbore ledge for cracks.
If surface C has signs of extreme wear, the counterbore will
require machining and the installation of shims for the correct
liner protrusion.
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Cylinder liner shims are available as follows:
Cylinder Liner Shim Thickness
mm Part No. in
0.25 1296 603 Hl 0.010
0.38 1296 604 Hl 0.015
0.51 1296 605 Hl 0.020
bp900gf
Cylinder Block - Group 01 Cylinder Block - Inspection For Reuse (l-06)
Measure the liner counterbore depth.
Cylinder Block Counterbore Depth From Cylinder

mm in
122.930 MIN 4.8397
123.000 MAX 4.6425
Cylinder Block Height From Cylinder Block Head Deck

mm in
309.4 MIN 12.181
309.6 MAX 12.189
ckSbdnt
Cylinder Block Height From Cylinder Block Head Deck

mm in
361.90 MIN 14.248
362.10 MAX 14.256
ck9bdr
Inspect the main bearing bores for wear or damage.

Install new main bearing and measure the bore diameter with
main bolts tightened.
Main Bearing Bore Diameter

mm in
With New Bearings 98.079 MIN 3.8614
98. i 25 MAX 3.8632
Without Bearings 104.982 MIN 4.1331
105.018 MAX 4.1346
NOTE:The maximum bore misalignment is 0.0127 mm
[0.0005 inch].
Expansion Plug - Installation (l-07) Cylinder Block - Group 01
Inspect the camshaft bores for scoring or excessive wear.

Measure the camshaft bores. Use a bore gauge The bores
must be measured in two positions. Take a second
measurement 90 degrees from the first measurement.
Camshaft Bore Diameter (Maximum)

mm in
64.01 (Without Bushing) 2.520
60.12 (With Bushing) 2.367
0
Inspect the tappet bores for scoring or excessive wear.
4B
Tappet Bore Diameter
@I mm
16.000 MIN
in
0.630
16.055 MAX 0.632
Expansion Plug - Installation (I-07)

Caution: Do not install any expansion plugs or pipe plugs
in the block until the inspection and any necessary repair
procedures are completed. This will prevent dirt from being
trapped in the oil passages.
Caution: Excessive sealant can run back into the engine
and cause damage to other components. Allow the sealant
to dry for a minimum of 2 hours before operating the
engine. The plug can come out of the bore if the sealant is
not dry.
Apply a 2 mm [l/l 6 inch] bead of expansion plug Lo&N Seal,
Part No. 3375066, or equivalent to the outside diameter of the
expansion plug and the inside diameter of the expansion plug
bore.
NOTE: Use an expansion plug driver to install the expansion
plug to the correct depth in the bore.
Use the following expansion plug drivers:
Tool P/N Exp. Plug P/N Exp. Plug Dimension

3822372 1240 151 Hl 0.375 inch
3823521 1240 200 Hl 0.8125 inch
3376816 1.00 inch
3823522 1240 889 Hl 1.1875 inch
3823523 1240 979 Hl 1.375 inch
3823524 1240 154 Hl 2.250 inch
Cylinder Block - Group 01 Expansion Plug - Installation (l-07)
Caution: Do not install the plug too deeply. The cross

drillings in the cylinder block may be blocked. If the plug
is not installed straight and flat, it must be replaced with
a new expansion plug.
A
The expansion plug must be installed with the edge of the
plug 0.5 to 1 .O mm [0.020 to 0.040 inch] deeper than the
entrance chamber of the bore.
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Pipe Plug - Installation

Apply a bead of pipe plug sealant, Part No. 3375066, or
equivalent to the threads.
Install and tighten the pipe plugs. Refer to the following chart
for torque values:
.ckBppha
Tighten pipe plugs to the appropriate torque values.

NOTE: The accompanying chart is also provided in Group 18
r Pipe Plug Torque Values
Size Torque Torque
“Specifications”.
ACiUd In Aluminum In cast IrOn or
Thread Thread O.D. Components Steel Components
in. mm PI Nom [ft-lbs] N-m [tt-lbsl

l/16 8.1 IO.321 5 [45 in-lb] 15 WI
l/8 10.4 [0.41] 15 DO] 20 1151
l/4 13.7 IO.541 20 1'51 25 [201
318 17.3 ]0.68] 25 [201 35 1251
l/2 21.6 [0.65] 35 [251 55 1401
3/4 28.7 [l.OS] 45 [35] 75 [551
1 33.5 11.32) 80 I451 95 1701
1v4 42.2 Il.861 75 1551 115 I851
1‘12 48.3 11.901 85 I651 135 ww
ck6ppoa
Pipe plug and expansion plug locations in front of cylinder @

block.
4W
1. 1 inch pipe plug
2. 13/16 inch expansion plug
3. l-3/8 inch expansion plug
5. l/2 inch pipe plug
Camshaft Bore Expansion Plug Installation (l-08) Cylinder Block - Group 01
Pipe plug and expansion plug locations, right side of block.

1. 2.287 inch expansion plug
8 5. 3/4 inch pipe plug
6. l/4 inch draincock
7. 3/8 inch expansion plug or dipstick tube
ck9PP’Ld
8. 7/8 inch expansion plug or turbocharger drain tube
Pipe plug and expansion plug locations, rear of block.

1. l-3/1 6 inch expansion plug or aftercooler connections
3. Camshaft bore expansion plug
ckWP9
Pipe plug and expansion plug locations, left side of block.

1. l-3/8 inch expansion plug on side oil fill
2. 3/4 inch pipe plug
4. 3/8 inch expansion plug or dipstick tube
Camshaft Bore Expansion Plug -

Installation (I-08)
Apply a bead of Loctite 27Pm around the outside diameter of
the camshaft expansion plug.
Cylinder Block - Group 01 Camshaft Bushing - Removal (l-09)
Position the plug with the convex side out.
Expand the plug with a large brass drift and a hammer
0623
Expand the plug until the convex side is even with the
cylinder block.
Camshaft Bushing - Removal (I-09)

Camshaft Bushing Removal and Installation Tool, Part No.
3823509
Drive the bushings from the cylinder block bore.
Camshaft Bushing Bore - Cleaning (l-lo) Cylinder Block - Group 01
Camshaft Bushing Bore - Cleaning (I-IO)

Use fine emery cloth and solvent to remove any burrs and
sharp edges from the bores.
II \ \\\I I I 1 I I cggt
Camshaft Bushing - Installation (l-11)

Mark the camshaft bushings and cylinder block to align the oil
holes.
NOTE: The oil holes in the camshaft bushings should be
pointing at approximately the 7:00 o’clock position when viewed
from the front of the engine.
Universal Bushing installation Tool

NOTE: The front camshaft bushing should be installed to a
depth of 4.5 mm [0.177 inch] below the front face of the
cylinder block. All other bushings are to be installed even with
the web of the camshaft bore.
Be sure the oil holes are aligned.
0
A 3.2 mm IO.128 inch] diameter rod must be able to pass
@ freely through the camshaft bushing oil hole.
Cylinder Block - Group 01 Cylinder Liners - Cleaning and Inspection for Reuse (1-12)
Measure the installed diameter of the camshaft bushings.
Camshaft Bushing Bore Diameter (Installed)

mm in
68.058 MIN 2.3645
68.112 MAX 2.367
Cylinder Liners - Cleaning and Inspection

for Reuse (l-l 2)
Cylinder Liners - Cleaning
Caution: To prevent cylinder liner damage, do not use a
hone or any abrasives in the ring travel area of the liner.
Abrasives can damage the surface finish and the cross
hatch pattern, and can contaminate the cylinder liner.
A
Use a soft wire brush to clean the flange seating area.
Use a fine fibrous abrasive pad such as; Scotch BriieQ 7448,
Part No. 3823258, or equivalent to remove the remaining
q\
bplcyed
scale and rust.

A
q
Use a non-metallic bristle brush, detergent soap, and warm
water to clean the inside diameter, \
Use a steam cleaner or a solvent tank to clean the liners.
Dry with compressed air.
Use clean 15W-40 oil to lubricate the inside diameter of the
liners.
Allow the oil to soak in the liner for five to ten minutes.
q
&
4
u bp2cyva
q
Use “lint-free” paper towels to wipe the oil from the inside of
the liners. \
0a.3
Continue to lubricate the inside of the liners and wipe clean
until the paper towel shows no gray or black residue.
Cylinder Liners - Cleaning and Inspection for Reuse (1-12)
614 Series
Page 1-24
Cylinder Liners - Inspection

Visually inspect the liners for cracks on the inside and outside
43 diameters.
3
Inspect for cracks under the flange.
cklslsa
Visually inspect the outside diameter and seat area for

excessive corrosion or pitting.
NOTE: Pits must not be more than 1.6 mm to.06 inch] deep.
Replace the cylinder liner if the pits are too deep or if the
corrosion cannot be removed with fine emery cloth.
Inspect the inside diameters for vertical scratches deep enough

to be felt with a fingernail.
NOTE: If a fingernail catches in the scratch, the cylinder liner
must be replaced.
Visually inspect the inside diameter for scuffing or scoring.
Cylinder Block - Group 01 Cylinder Liners - Cleaning and Inspection for Reuse (1-12)
Visually inspect the inside diameter for liner bore polishing.

A moderate polish (A) produces a bright mirror finish in the
4B
0‘
worn area with traces of the original hone marks or an
indication of an etch pattern.
A heavy polish (B) produces a bright mirror finish in the
worn area with no traces of hone marks or an etch pattern.
(4 I (B) Ck3SlSC
0a3
Replace the liner if:
l A heavy polish is present over 20 percent of the piston
ring travel area.
l 30 percent of the piston ring travel area has both
moderate and heavy polish and one half (15 percent)
is heavy polish.
L15% ck8slsd
Part No. 3375072, Dial Bore Gauge

Use a dial bore gauge to measure the liner inside diameter in
four places 90 degrees apart at the top and bottom of the
piston travel area.
Cylinder Liner I.D.

mm in
114.000 MIN 4.4882
114.117 MAX 4.4928
Measure the outside diameter of the liner top press fii area.
Cylinder Liner O.D. (Top Press Fit)

mm in
132.938 MIN 5.2338
132.958 MAX 5.2343
Pistons - Cleaning and Inspection for Reuse (1-13) Cylinder Block - Group 01
Pistons - Cleaning and Inspection for

Reuse (l-l 3)
Piston Rings - Removal
Part No. 3823137, Piston Ring Expander
Remove the piston rings.
RI Place a tag on the rings and record the cylinder number of the
piston on the tag.
pG00fb
@ l
Pistons - Cleaning
Caution: Be sure the cleaning solvent is approved for
aluminum. Damage to the pistons can result.
A
Allow the pistons to soak for a minimum of 30 minutes in a
tank containing an approved cleaning solvent for aluminum.
NOTE: For the best results, let the pistons soak for several
hours or overnight.
Use a hot, soapy solution and a non-metallic brush to remove
carbon deposits.
Caution: Do not use a metal brush. A metal brush will

damage the piston ring grooves. Do not use glass beads to
clean the grooves. Walnut shell or plastic bead blasting
may be used on grooves with a ni-resist insert and on the
dome or crown of the piston. Use the minimum effective
pressure and do not concentrate the spray in one area for
an extended period of time. The recommended blast
pressure for plastic bead blasting is: 276 kPa [40 psi]. Do
not use glass beads or walnut shell blasting on the
aluminum grooves or pin bores. This can cause the pin
bore to crack or the rings to not seat.

A clothing and safety glasses or a face shield. Hot steam will
q
B Use steam to clean the pistons.
Cylinder Block - Group 01 Pistons - Cleaning and Inspection for Reuse (1-13)
Pistons - Inspection
inspect the piston for damage and excessive wear. Check
the piston ring grooves, skirt and pin bore.
NOTE: Dimensional inspection of the piston is required only
when the cause of the lack of sealing is not apparent.
pi900sb
0a9
Visually inspect the piston bowl (l), pin bore (2) and skirt (3)
for cracks or damage.
NOTE: Do not use pistons with cracks.
Measure the piston pin bore when the piston temperature is

at 20°C [SSOF].
Piston Pin Bore I.D.

mm in
45.006 MIN 1.7719
45.025 MAX 1.7726
NOTE: Add 0.013 mm [0.0005 inch] to the bore inside di-

ameter per 5°C [lO”F] temperature rise up to 32°C [9O”F].
Q pi9brta
04iB
Visually inspect the piston pin for scratches, grooves, or
other damage. $
Measure the piston pin outside diameter.
-O-
a:
Piston Pin O.D. 4
mm in
44.993 MIN 1.7714
45.003 MAX 1.7718
NOTE: Discard the piston pin if it is more than 0.03 mm

[O.OOl inch] out of round pl9pita
Crankshaft - Cleaning and Inspection for Reuse (l-14) Cylinder Block - Group 01
Measure the piston skirt diameter as illustrated.
Piston Skirt O.D.

mm in
113.814 MIN 4.4810
113.886 MAX 4.4840
pi9bdta 1
Use a micrometer and Part No. 3823966, piston ring groove

gauge, to measure the wear of the top ring groove keystone
angle. Use Part No. 3823965, piston ring groove gauge, to
measure the wear of the intermediate ring groove keystone
angle.
Piston Ring Groove (Keystone Angle)

Ring mm in
Top: 113.938 MIN 4.4857
Use a new piston ring and feeler gauge to measure the side
clearance of the rectangular intermediate and oil control ring
grooves.
Piston Ring Clearance (Rectangular Groove)

Ring mm in
0.150 MAX 0.0030
Oil Control: 0.020 MIN 0.0008
0.130 MAX 0.0051
pi900ta
Crankshaft - Cleaning and Inspection for

Reuse (l-l 4)
Crankshaft - Cleaning
Use fine crocus cloth to polish the machined surfaces.

Use a bristle brush to clean the oil drillings.
614 Series
A
Steam clean the crankshaft and dry with compressed air.
Make sure to blow out the threaded
the crankshaft and the oil drillings.
holes on each end of
q
\
Crankshaft - Inspection
Visually inspect the threaded capscrew holes for damage.
Use one of the following
holes:
methods to repair any threaded 04iB
l Chase the threads
l Use the Part No. 3822709, Threaded Insert Kii
NOTE: If more than two threaded holes are damaged in one
end, the crankshaft must be replaced.
Measure the front and rear oil seal contact areas for a wear
groove.
Crankshaft Front and Rear Oil Seal Wear Groove

mm in
0.25 MAX 0.010
Front and rear wear sleeves are available for a crankshaft

that is worn beyond the limit.
0a3
Inspect the crankshaft connecting rod and main journals for
deep scoring, overheating, etc.
Crankshaft - Cleaning and Inspection for Reuse (1-14) Cylinder Block - Group 01
Use a micrometer to measure the connecting rod journal.
Connecting Rod Bearing Journal Diameter (Min.)

mm in
75.962 Standard 2.9906
75.712 Machined 0.25 mm 2.9808
75.462 Machined 0.50 mm 2.9709
75.212 Machined 0.75 mm 2.9611
74.962 Machined 1.00 mm 2.9513
Bearing Clearance = Connecting rod inside diameter with
bearing installed minus crankshaft journal diameter.
Maximum Bearing Clearance: 0.1 17 mm [0.0046 inch]
Connecting Rod Bearing Journal

mm in
Out-of-Roundness: 0.050 MAX 0.0020
Taper: 0.013 MAX 0.0005
ks.9001
Main Bearing Journal Diameter (Minimum)

mm in
97.962 Standard 3.8568
97.712 Machined 0.25 mm 3.8469
97.462 Machined 0.50 mm 3.8371
Bearing Clearance = Main bore diameter with bearing installed

minus (-) crankshaft main journal diameter.
Maximum Bearing Clearance: 0.134 mm [0.0053 inch]
Crankshaft Main Bearing Journal

mm in
Out-of-Roundness: 0.050 MAX 0.0020
Taper: 0.013 MAX 0.0005
ks900nd
Cylinder Block - Group 01 Crankshaft - Cleaning and Inspection for Reuse (1-14)
6i4 Series Page 1-31
The following oversize service main and thrust bearings are

available for crankshafts that have been machined undersize:
Main Bearing Diameter

Oversize 0.000 0.25 mm 0.50 mm
Thrust 0.000 X X X
Bearing 0.25 mm X X
Diameter 0.50 mm X X
ks9OOad
Measure the thrust face width.
Crankshaft Thrust Face Width (Standard)

mm in
42.975 MIN 1.6919
43.076 MAX 1.6959
ks2OOnc I
Measure the rear oil seal flange outside diameter.
Crankshaft Rear Oil Seal Flange O.D.

mm in
129.975 MIN 5.1171
130.025 MAX 5.1191
ks200
Measure the damper pilot outside diameter.
Crankshaft Damper Pilot O.D.

mm in
23.924 MIN 0.9419
24.000 MAX 0.9449
ks200nl
Crankshaft Gear - Replacement (1-15) Cylinder Block - Group 01
Use a light preservative oil to lubricate the crankshaft to

cl
Di prevent rust.
If the crankshaft is not going to be used immediately, protect
the part with a plastic cover to prevent dirt from sticking to the
oil.
ks200wt
Crankshaft Gear - Replacement (1-15)

General Information
There are two different crankshaft gears used:
Steel gear for engines with a Bosch PESGP fuel injection
pump.
Austempered gear for engines without a Bosch PESGP fuel
injection pump.
-I
Crankshaft Gear - Removal
I Use a heavy duty bearing separator or gear puller as illustrated
to remove the gear.
NOTE: The bearing separator or gear puller must be used to
remove the steel gear; however, a gear splitter can be used to
remove the austempered gear if it is not intended to be used
again.
Refer to the following procedure:
Part No. 3823585, Crankshaft Gear Splitter

Caution: Safety glasses are required when using this tool.
Caution: Use care to avoid damage to the polished surfaces
of the crankshaft by driving the point of the tool into the
crankshaft.
bp900gk
Cylinder Block - Group 01 Crankshaft Gear - Replacement (1-15)
Place the point of the chisel between two gear teeth. I I
Strike the splitter with a two or three pound steel hammer.

Repeat this step if necessary.
Use a dowel pin extractor to remove the gear alignment
dowel pin.
Crankshaft Gear - Inspection

Visually inspect for cracks and broken or chipped teeth.
The gear must be replaced if it is damaged. 0a3
Visually inspect the gear and keyway for nicks or burrs.

Use fine crocus cloth to remove nicks and burrs.
ksagesb
0a3
Visually inspect the crankshaft gear journal and the gear
alignment dowel pin hole for burrs or damage.
Use fine crocus cloth to remove burrs.
q
\
Crankshaft Gear - Replacement (l-15) Cylinder Block - Group 01
Measure the crankshaft gear journal inside diameter.
Crankshaft Gear Journal I.D.

mm in
75.698 MIN 2.9661
75.923 MAX 2.9691
kslgeta
u Measure the crankshaft gear journal outside diameter.
Crankshaft Gear Journal O.D.

mm in
75.987 MIN 2.991
76.006 MAX 2.992
kslgetb
Crankshaft Gear - Installation

Use a soft hammer to install the gear alignment dowel pin into
the crankshaft.
The pin must be 1.02 mm IO.040 inch] above the crankshaft
surface.
Caution: Do not exceed the specified heating time or

temperature. The crankshaft gear and teeth can be
damaged.
Heat the gear in an oven for a minimum of 45 minutes but not
more than six hours.
Austempered Gear - Temperature: 149°C [300” F]
Steel Gear - Temperature: 177°C [350” F]
Cylinder Block - Group 01 Main Bearings - Cleaning and Inspection for Reuse (1-16)
1
Use LubriplaW No. 105, or equivalent to lubricate the
outside diameter of the crankshaft gear journal.
Caution: Use insulated gloves, Part No. 3823730,

handling heated parts. Personal injury will result.
Caution: The timing mark (1) and part number (2) on the
when
A
gear must be facing away from the crankshaft after the
gear is installed. Engine damage can result if the gear is
installed backwards.
Remove the gear from the oven.
Align the keyway of the gear with the alignment dowel pin in
the crankshaft and install the gear within 30 seconds. @j@
Caution: Do not use water or oil to reduce the cooling
time. The gear can crack. Allow air to cool the gear.
NOTE: If the gear cools and stops on the crankshaft before

it is fully installed, use a driver to complete the installation.
I I ks9geh
Main Bearings - Cleaning and Inspection

for Reuse (I-16)
General Information
The engine has seven main bearings. The lower bearing
shells are all the same. The upper bearings have two oil
holes, the lower bearings do not have holes. All of the upper
bearing shells are the same except for the No. 4 journal. The
No. 4 journal uses a flanged upper bearing shell. The flanges
on the bearing control the end thrust of the crankshaft.
ks9OOgd
Main Bearings - Cleaning and Inspection for Reuse (l-16) Cylinder Block- Group01
Main Bearings - Cleaning

Make sure the bearings are marked for location.The bearings
must be installed in their original location if used again.
Caution: Do not use a scraper or a wire brush. The
bearings can be damaged.
Use solvent and a soft bristle brush.
Main Bearings - Inspection

Visually inspect for nicks, scratches or damage.
Replace any bearings with the following damage:
l Pitting
l Flaking
l Corrosion
l Lock tang damage
l Scratches (deep enough to be felt with a fingernail)
NOTE: For more detailed information of bearing damage, refer
to “Analysis and Prevention of Bearing Failures,” Bulletin No.
mb2OOsa 3810387.
Use an outside diameter ball tipped micrometer to measure the

main bearing shell thickness at the wear location.
Standard Main Bearing Shell Thickness (Used)

mm in
3.340 MIN 0.131
3.454 MAX 0.136
Discard any main bearing shell if its thickness is below the

minimum specification.
Bearing shells are identified by steel stamped characters on the

back of the bearings to indicate either standard (STD) or the
amount of oversize (OS).
mb9bept
Cylinder Block - Group 01 Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse (1-17)
The following oversize service main and thrust bearings are

available for crankshafts that have been machined undersize:
Main Bearing Diameter

Oversize 0.000 0.25 mm 0.50 mm
Thrust 0.000 X X X
Bearing 0.25 mm X X
Diameter 0.50 mm X X
ks9OOad
Thrust Bearings - Inspection
0
Visually inspect the thrust bearings for wear, cracks or
damage on the front and rear face and also the crankshaft @
journal contact area.
mb9bel
Measure the thrust bearing flange thickness. Measure both

the front and rear face contact areas.
Thrust Bearing Flange Thickness

mm in
3.417 MIN 0.1345
3.530 MAX 0.1339
NOTE: Thrust bearings are available in 0.25 mm [O.OlO-inch]

and 0.50 mm [0.020-inch] oversize thicknesses. Refer to the s@S
chart above.
Main Bearing Caps and Capscrews -

Cleaning and Inspection for Reuse (1-17)
Cleaning
Use solvent and a soft bristle brush to clean the main
bearing cap, capscrews and bearings. Dry with compressed
air.
mb9caea:
Connecting Rod Bearings - Cleaning and inspection for Reuse (1-18) Cylinder Block - Group 01
Page 1-38 _ 614 Series
Inspection
0623 Visually inspect the main cap and capscrews for damage.
Connecting Rod Bearings - Cleaning and

Inspection for Reuse (l-l 8)
NOTE: For future identification, the bearings must be marked
for location as they are removed. Each bearing must be
installed in its original location if the bearing is used again.
Connecting Rod Bearings - Cleaning
Caution: Do not use a scraper or a wire brush. The
A bearings can be damaged.
q
\ Use solvent and a sofi bristle brush. Dry with compressed air.
Connecting Rod Bearings - Inspection

Visually inspect the bearings for damage.
Replace any bearings with the following damage:
l Pitting
l Flaking
l Corrosion
l Lock tang damage
l Scratches (deep enough to be felt with a fingernail)
Refer to the Parts Reuse Guidelines, Bulletin No. 3810303, for
further information.
0a?
NOTE: Normal bearing wear produces a smooth finish which
will wear into the lining. An exposed lining does not always
indicate worn bearings. If large areas of the lining are visible in
the bearings before the engine has accumulated 240,000
kilometers [150,000 miles] or 3,750 hours, inspect the engine
for contamination from fine dirt particles and correct the
problem.
I cx8beba
Cylinder Block - Group 01 Connecting Rods - Cleaning and Inspection for Reuse (l-19)
0@
Visually inspect the bearing seating surface for nicks or
burrs.
If burrs can not be removed with a fine crocus cloth, the
bearings must be replaced.
For more detailed information of bearing damage, refer to e
Analysis and Prevention of Bearing Failures, Bulletin No.
3810387.
Measure the connecting rod bearing shell thickness with an

outside micrometer that has a ball tip.
Standard Connecting Rod Bearing Thickness

mm in
2.43 MIN 0.0958
2.471 MAX 0.0973
Discard a bearing shell if its thickness is below the minimum

specification.
mbabetb
NOTE: Oversize bearing shells are available for crankshafts

which are 0.25 [O.OlO-inch], 0.50 mm [0.020-inch], 0.75 mm
[0.030-inch], or 1.OO mm [0.040-inch] undersize.
Bearing shells are identified by steel stamped characters on Standard
the back of the bearings to indicate either standard (STD) or
the amount of oversize (OS). Oversize
Refer to the appropriate Parts Catalog.
0.25 mm (.OlO in.)
0.50 mm (.020 in.)
0.75 mm (.030 in.)
1.00 mm (-040 in.)
mb9OOgb
Connecting Rods - Cleaning and

Inspection for Reuse (1-I 9)
Connecting Rods - Cleaning
NOTE: The letter or number on the connecting rod cap must
be the same as the letter or number on the connecting rod.
Do not assemble a new cap to a used connecting rod or a
used cap to a new connecting rod.
Remove the connecting rod capscrew nuts and caps from
the connecting rods.
Connecting Rods - Cleaning and Inspection for Reuse (1-19) Cylinder Block - Group 01

Use solvent or steam to clean the rods.
Use a soft bristle brush to clean the oil drilling.
cx900ea
Connecting Rods - Inspection
0@3
Visually inspect the connecting rod and cap for fretting damage
on the mating surfaces.
The rod and cap must be replaced as an assembly if any
fretting damage is visible on either piece.
Replace the connecting rod if the “l-beam” is nicked or
damaged.
Visually inspect the connecting rod pin bore bushing for

@
0
damage or misalignment of the oil passage and bushing.
900sd
Measure the connecting rod piston pin bushing inside diameter.

CB Connecting Rod Pin Bore Diameter (Bushing
Installed)
mm in
45.023 MIN 1.7726
45.060 MAX 1.7740
NOTE: Service replacement rod bushings are available. Refer
to the appropriate parts catalog for part numbers.
The bushing must be precision machined after installation. If
cx9brta machining capability is available, the bushing can be replaced.
Refer to Connecting Rod Bushing - Replacement in
Procedure l-21.
Cylinder Block - Group 01 Connecting Rods - Cleaning and Inspection for Reuse (1-19)
Tap the connecting rod bolts in until the head is aligned and
seated on the flat machined surface of the connecting rod.
cx9basa
Install the bearing shells into the connecting rod and cap.
@A
Use clean 15W-40 oil to lubricate the capscrew threads. 47
Install the connecting rod caps and connecting rod nuts.
NOTE: The connecting rod cap number must match the
number on the connecting rod and be installed with the
numbers aligned.
Tighten the connecting rod nuts in alternating sequence.
0%
Torque Value: Step 1 - 40 Nom [30 ft-lb]
Step 2 - 80 Nom [60 h-lb]
Measure the connecting rod crankshaft bore inside diameter

with the bearing installed.
Connecting Rod Crankshaft Bore I.D.

mm in
76.046 MIN 2.9939
76.104 MAX 2.9962
Caution: The connecting rod must be assembled with the

capscrew nuts tightened to specifications before stamping
the cylinder identification number on the connecting rod.
If a new connecting rod is installed, always stamp the new
connecting rod with the cylinder number of the rod being
replaced.
Connecting Rods - Bend and Twist Inspection (l-20) Cylinder Block - Group 01
Connecting Rods - Bend and Twist

Inspection (I-20)
Fixture Calibration
Use a connecting rod checking fixture, Part No. ST-561, and a
connecting rod mandrel set, Part No. 3823286, to inspect the
bend and twist of the rods.
Calibrate the checking fixture with a new rod that has been
measured for correct center to center length, 215.975 mm to
216.025 mm [8.5029 inches to 8.5049 inches].
cx8togd
NOTE: Assemble the connecting rod cap to the rod as
described in Procedure 1-19.
Install the piston pin mandrel from the connecting rod mandrel
set, Part No. 3823286, into the piston pin bore.
NOTE: Use a mandrel, Part No. 3823283, if the piston pin
bushing has been removed or mandrel, Part No. 3823284, if the
bushing is still in place.
Install the mandrel, Part No. 3823303, into the crankshaft bore
and expand the mandrel.
NOTE: Make sure the pin on the mandrel is pointed down and
locked in position in the center of the connecting rod.
cx9toh;
Install the connecting rod into the fixture.

Move the dial holder to position the contact points of the
indicators on the mandrel in the piston pin bore.
Tighten the bracket to hold the indicators in position.
Set the dial indicators to read zero.
Remove the connecting rod from the fixture.

Turn the rod 180 degrees horizontally, and install the rod into
the fixture again.
Cylinder Block - Group 01 Connecting Rods - Bend and Twist inspection (l-20)
0+B
Check the dial indicators for the zero position again.
If the dial indicators show any change from zero, adjust the
dials to half the indicated reading.
The fixture is now calibrated to allow the connecting rod to
be installed into the fixture in either direction, and the dials
will indicate an equal deflection on either side of zero.
Connecting Rod Alignment - Inspection

Install the mandrel and arbor into the connecting rod to be
inspected.
Install the connecting rod into the fixture.
Measure the connecting rod length and bend (alignment).
Connecting Rod Length

mm in
215.975 MIN 8.5029
216.025 MAX 8.5049
Connecting Rod Bend (Alignment)

mm in
Bushing Removed 0.20 MAX 0.008
Bushing Installed 0.15 MAX 0.006
Connecting Rod Twist - Inspection

Install a feeler gauge between the mandrel and the dial
indicator holding plate as shown.
Connecting Rod Twist

mm in
Bushing Removed 0.50 MAX 0.020
Bushing Installed 0.30 MAX 0.012
Connecting Rod Bushing - Replacement (1-21) Cylinder Block - Group 01
Connecting Rod Bushing - Replacement

(1-21)
Part No. 3823690, Connecting Rod Pin Bore Bushing
RI Removal/Installation Tool
This tool is used to remove and install the bushings to the
correct position.
Ref.
No. Part No. Description QW
1 3823691 Anvil 1
cx9toga
2 3823693 Cup 1
3 3823692 Mandrel 1
4 3823694 Driver Ring (thick) 1
5 3823695 Knock-out-ring (thin) 1
6 Hair Pin Cotter 1
Removal
Place the pin bore end of the connecting rod on the mandrel.
cx9toht
0
Place the knock-out (thin ring) on the mandrel on top of the
4B connecting rod. Match up the angle surfaces.
cx9tohc
Cylinder Block - Group 01 Connecting Rod Bushing - Replacement (l-21)
Install the cup on the mandrel and secure with the hair pin
cotter.
Install the mandrel in the anvil. Place the connecting rod so

the angle on the rod matches with angle on the anvil. The
connecting rod will be in the horizontal position.
cx9toh
Press the connecting rod bushing out by applying force on

top of the cup. Press the bushing through the bore. 0
C%
Remove the hair pin cotter.

Remove the cup and slide the connecting rod from the
mandrel.
@@
Measure the connecting rod bushing bore with the bushing

removed.
NOTE: If the connecting rod bushing bore is not within
specifications, replace the connecting rod.
Connecting Rod Pin Bore Diameter (Bushing

Removed)
mm in
46.966 MIN 1.9266
49.012 MAX 1.9296
cx9bsn;
Installation
Before installing the connecting rod bushing, submerge the
bushing and connecting rod pin end in clean 15W-40 engine
oil.
Place the connecting rod bushing on the mandrel.
Place the knock-out (thin ring) inside the driver ring.
Match the angles, place the angle side down and align the
notch of the knock-out (thin ring) to the pin in the driver ring
and slide on the mandrel.
Cylinder Block - Group 01 Connecting Rod Bushing - Replacement (1-21)
Install the cap and secure with the hair pin cotter.
Insert the mandrel and components into the chamfered side

of the connecting rod.
Align the angles of the bushing, connecting rod, and stop
rings.
NOTE: All connecting rods do not have a double chamfer. A
chamfer may be added to aid in the installation of the
bushing, but should not result in an unsupported bushing
area.
0ai3
Align the oil hole in the bushing and connecting rod (use the
groove in the mandrel) and push the mandrel and
components into the pin bore of the connecting rod until
contact is made. This contact helps maintain the alignment of
the oil holes.
Place the connecting rod and mandrel assembly on the anvil

(position so that the angle on the connecting rod matches
the angle on the anvil). The connecting rod is in the
horizontal position.
Press the bushing into the connecting rod by applying force on

the top of the cup. Use either an arbor or hydraulic press.
Push through in a continuous motion until the driver ring makes
contact with the connecting rod.
cx9bshc
Check the alignment of oil holes. A 3 mm [l/8 in] diameter rod

must move freely through the connecting rod and the bushing
oil holes (A).
Check for clearance between the connecting rod bushing and
the connecting rod.
Use a 0.025 mm [O.OOl inch] feeler gauge to make sure the
bushing is properly seated. The 0.025 mm [O.OOl inch] feeler
gauge must not enter between the bushing and the connecting
rod (B).
cx9bsnt
Machining
The inside diameter of new connecting rod bushings must be
machined with a rod boring machine such as Part No. 3823801
(Sunnen PM-300@) or Part No. 3375144 (Tobin Arp@).
When properly adjusted, a Sunnen PM-300@, or equivalent,
connecting rod boring machine is capable of maintaining all the
critical dimensions.
NOTE: Do not use a “floating rod” type honing machine.
Inspection
NOTE: After machining the connecting rod bushings, it will be
necessary to check all critical dimensions. Refer to Procedure
1-19 in this section for specifications and instructions.
cx9brta
Cylinder Block - Group 01 Camshaft - Cleaning and Inspection for Reuse (l-22)
6i4 Series Page l-49
Camshaft - Cleaning and Inspection for

Reuse (I-22)
Camshaft - Cleaning
A
Use solvent or
compressed air.
steam clean the camshaft. Dry with
q
\
Caution: After the camshaft has been steam cleaned, do

not touch the
will cause rust
15W-46 engine
machined surfaces with bare hands, this
to form. Lubricate the camshaft with clean
oil before handling.
A
Camshaft - Inspection
Visually inspect the fuel transfer pump lobe, valve lobes and
bearing journals for wear, cracking, pitting, scratches or other
damage.
0423
NOTE: Komatsu Dresser Company does not recommend
repairing camshafts by grinding the valve lobes.
If the camshaft is damaged beyond the reuse guidelines, the
camshaft must be replaced.
The following criteria defines the size of the pits, allowable
wear and edge deterioration of the chilled iron camshaft
lobes.
0QB
Pitting:
A single pit must not be greater than the area of a 2 mm
IO.079 inch] diameter circle.
Camshaft - Cleaning and Inspection for Reuse (l-22) Cylinder Block - Group 01
0
Interconnection of pits is not allowable and is treated as one
a3 pit.
cg900sd
The total pits, when added together, must not exceed a circle
0
a? of 6 mm [0.236 inch].
cgsoose
0
Only one pit is allowed within + or - 20 degrees of the nose of
a3 the camshaft lobe.
Measure across the peak of the camshaft lobes.

@
6
Camshaft Lobe Wear Limits (Minimum)
mm in
51.774 Intake Valve 2.038
0 51.596
41.31
Exhaust Valve
Fuel Transfer Pump
2.031
1.626
t cg9oosg
Cylinder Block - Group 01 Camshaft - Cleaning and Inspection for Reuse (l-22)
Measure across the camshaft journal.
Camshaft Journal Diameter

mm in
59.962 MIN 2.3607
60.013 MAX 2.3627
NOTE: Replace the camshaft if the outside diameter of any

bearing surface is less than 59.962 mm [2.3607 inch].
Edge Deterioration (Breakdown)

The area of edge deterioration must not be greater than the
equivalent area of a 2 mm [0.079 inch] circle within + or -
20 degrees of the nose of the camshaft lobe.
Outside of the + or - 20 degrees of the nose of th

camshaft lobe, the areas of edge deterioration must not b
greater than the equivalent area of a 6 mm [0.236 inch]
circle.
Camshaft - Cleaning and Inspection for Reuse (l-22) Cylinder Block - Group 01
0
This illustration shows normal grain pattern and a casting flaw within the nose
49 area. Both of these conditions are acceptable for reuse.
The folk )wing three illustrations show wear patte rns that are not acceptable for reu se:
_
Camshaft Gear - Inspection
0623 Visually inspect the camshaft gear teeth for wear and damage.
Look for cracks at the root of the camshaft gear teeth. If the
gear is damaged, it must be replaced. Refer to Procedure l-23.
Cylinder Block - Group 01 Camshaft Gear - Replacement (l-23)
Camshaft Gear - Replacement (l-23)

Camshaft Gear - Removal
A
Caution: Place a wooden block under the camshaft to
avoid damage as the camshaft drops free from the
camshaft gear.
Place the camshaft and gear assembly in the hydraulic press.
Push the camshaft from the gear.

Remove the camshaft dowel pin.
cgegemd
Camshaft Gear - Cleaning
q
Use solvent to clean the camshaft gear. Dry with compressed
air. \
Camshaft Gear - Inspection

Visually inspect
broken teeth.
the camshaft gear for cracks,
Inspect the bore of the gear for fretting or burrs.

chipped, or
06B
NOTE: If the fretting, burrs, or raised material cannot be
removed with Scotch-BriteQ 7448, or equivalent, replace the
gear.
Camshaft Gear - Replacement (l-23) Cylinder Block - Group 01
inspect the camshaft gear keyway for burrs.

Remove burrs with Scotch-BriieQ 7446, or equivalent.
NOTE: If the keyway is damaged or the burrs cannot be
removed, the camshaft gear must be replaced.
Measure the camshaft gear bore inside diameter.
Camshaft Gear Bore I.D.

mm in
41.480 MIN 1.633
41.505 MAX 1.634
Visually inspect the camshaft nose for fretting or burrs.

0
a3 NOTE: If fretting or burrs cannot be removed with
Scotch-BriteQ 7448, or equivalent, replace the camshaft.
Measure the camshaft gear journal outside diameter.
Camshaft Gear Journal O.D.

mm in
41.56 MIN 1.636
41.58 MAX 1.637
Cylinder Block - Group 01 Camshaft Gear - Replacement (l-23)
Measure the camshaft thrust plate thickness.
Camshaft Thrust Plate Thickness

mm in
9.34 MIN 0.368
9.58 MAX 0.377
Camshaft Gear - Installation

Use a leather hammer to install the camshaft gear dowel pin. ($$A
@sP
cg9keha
Lubricate the camshaft gear journal with Lubriplatem 105.
Steel Camshaft Gear
A
Warning: Use insulated gloves, Part No. 3823730, when
handling heated parts. Hot parts will cause serious
personal injury.
Heat the gear in an oven for a minimum of 45 minutes, but
not longer than six hours.
Temperature: 177” C 1350” F]
Gear Housing - Cleaning and Inspection for Reuse (l-24) Cylinder Block - Group 01
Austempered Camshaft Gear

Heat the gear in an oven for a minimum of 45 minutes, but not
longer than six hours.
Caution: The gear will be permanently distorted if over
heated. The oven temperature should never exceed the
specification.
Temperature: 149°C [3OO”F]
Caution: To prevent engine damage, the timing marks and
A gear part number must be facing away from the camshaft

when the gear is installed.
Caution: Keep the camshaft in a vertical position with the
gear up until the gear has cooled. Do not use water to
reduce the cooling time. Using water will crack the gear.
NOTE: The gear must be installed within 30 seconds after it is
removed from the oven.
@ Remove the camshaft gear from the oven. Align the keyway in
the camshaft gear with the dowel pin in the camshaft and
install the gear on the camshaft. Be sure the gear is seated
against the camshaft shoulder.
Gear Housing - Cleaning and Inspection

for Reuse (l-24)
Gear Housing - Cleaning
A Warning: When using a steam cleaner, wear protective

El
lb Use steam or solvent
compressed air.
to clean the gear housing. Dry with
Gear Housing - Inspection
0
623 Visually
sealing
inspect the
surfaces.
gear housing for cracks or damaged
Cvlinder Block - Group 01 Gear Housing - Cleaning and Inspection for Reuse (l-24)
0a3
Inspect the timing pin housing and pin for damage.
Do not remove the timing pin assembly unless it is damaged
or leaking, or the gear housing is being replaced.
NOTE: The location of the timing pin assembly on the gear
housing is critical for correct engine adjustments. If the e
original gear housing is being installed, it is unnecessary to
relocate the timing pin. If a new housing is being installed,
refer to Procedure‘ O-02 for timing pin installation and
adjustment.
15 mm
Visually inspect the fuel injection pump mounting studs for Eil
0@iPf
damage.
To install or remove fuel injection pump studs, use. two nuts
locked together on the stud.
Q&
g@
15 mm
If the fuel injection -pump mounting studs are damaged or
being installed in a new housing, coat the threads with
LoctiteTM 242 and use two nuts locked together to remove
and install.
1-1 fp900hz

If the gear housing is being replaced, remove the engine
dataplate and install on the new housing. Refer to Procedure
l-25.
Engine Dataplate - Replacement (l-25) Cylinder Block - Group 01
Engine Dataplate - Replacement (1-25)

The engine dataplate shows specific information about the
engine. The engine serial number and engine part number
provide information for ordering parts and service needs.
The dataplate must remain with the engine. If the gear housing
is replaced, remove the dataplate and install it on the new
housing.
Engine Dataplate - Removal

Remove the rivets that secure the dataplate to the gear
housing.
Engine Dataplate - Installation

NOTE: Be careful not to drive the rivets in too deep and
damage the dataplate.
2.0 mm Drill Bit

If the dataplate is loose or has been damaged, drill new holes
and attach with new rivets. Mark the drill bit at 6.0 mm [0.236
inch] to avoid drilling too deep into the gear housing.
Cvlinder Block - Group 01 Gear Cover - Cleaning and Inspection for Reuse (l-26)
Drill the dataplate, taking care not to destroy any information

printed on the dataplate.
Drive the rivets in until they contact the dataplate.
Gear Cover - Cleaning and Inspection for

Reuse (I-26)
Gear Cover - Cleaning
Use a gasket scraper or Scotch-Brite@ 7448 to remove all
gasket material.
Clean the gasket sealing surfaces and the surface between
the oil seal and gear cover.
q
\
A
Steam clean the gear cover. Dry with compressed air.
Gear Cover - Inspection
0a3
Visually inspect the gear cover for flatness, cracks, dents, or
other damage.
If the gear cover is bent or cracked, it must be replaced.
Vibration Damoer - Cleaning and Checking for Reuse (l-27) Cylinder Block - Group 01
Page l-60 . 614 Sbries
Vibration Damper - Cleaning and

Checking for Reuse (l-27)
General Information
NOTE: There are two different design vibration dampers used:
l Viscous damper (A) for certain engines rated at speeds
above 2500 RPM.
l Rubber element damper (B) for engines rated at speeds
below 2500 RPM. The rubber damper is available either
B with or without the crankshaft adapter.
da9puga
Rubber Vibration Damper - Cleaning
\
q
Use a mild detergent or solvent to clean the vibration damper.
Rubber Element Vibration Damper - Inspection
0623
Check the index lines (A) on the vibration damper hub (B) and
the inertia member (C). If the lines are more than 1.59 mm
[l/16 inch] out of alignment, replace the vibration damper.
Inspect the vibration damper hub (B) for cracks. Replace the
vibration damper if the hub is cracked.
da9OOse
Inspect the rubber member for deterioration. If pieces of rubber

are missing or if the elastic member is more than 3.18 mm
[l/8 inch] below the metal surface, replace the vibration
damper.
NOTE: Also look for forward movement of the vibration damper
ring on the hub. Replace the vibration damper if any movement
is detected.
da9OOsb
Cylinder Block - Group 01 Vibration Damper - Cleaning and Checking for Reuse (l-27)
Viscous Vibration Damper - Cleaning
A
Clean the vibration damper with a solvent cleaner or steam
clean. Dry with compressed air. q
\
Viscous Vibration Damper - Inspection

Check the mounting web for cracks. Check the housing for
dents or raised surfaces. Replace the vibration damper if any
of these defects are identified.
0
@
da9OOsd
The viscous vibration damper is filled with a silicone fluid.

After many hours of use, the silicone fluid can become
thicker and expand. To determine if the vibration damper
thickness is correct, remove the paint from the vibration
damper in four locations on either side of the vibration
damper. Measure and record the thickness of the vibration
damper in four places. Measure the thickness 3.18 mm
[0.125 inch] from the outside of the vibration damper.
Replace the vibration damper if its thickness varies by more
than 0.25 mm [O.OlO inch].
Spray the vibration damper with spot check developer, Type

SKD-NF or its equivalent. Heat the vibration damper in an
oven (rolled lip side down) at 93°C [2OO”F] for 2 hours.
Rear Cover - Cleaning and Inspection (l-28) Cylinder Block - Group 01
A Caution: Wear protective gloves to prevent personal injury

when handling parts that have been heated.
Remove the vibration damper from the oven and check for fluid
l leakage. If there is leakage, replace the vibration damper.
@
0a9
da9OOsf
Rear Cover - Cleaning and Inspection

(l-28)
Use a mandrel or drift to remove the crankshaft oil seal.
Cleaning
u
B Remove the gasket material from the rear cover gasket sealing
surface.
q
Use sovent to clean the rear cover. Dry with compressed air.
B
Cylinder Block - Group 01 Cylinder Head Capscrews - Cleaning and Inspection for Reuse (l-29)
Inspection
Inspect the rear cover for cracks or other damage.
Measure the rear cover crankshaft seal bore.

The rear cover must be clamped to a flat surface for
checking.
Rear Cover Crankshaft Seal Bore I.D.

mm in
149.96 MIN 5.904
150.04 MAX 5.907
Reolace the rear cover if the crankshaft seal bore is not I

within specifications.
Cylinder Head Capscrews - Cleaning and

Inspection for Reuse (l-29)
A
Caution: Prevent damage to the capscrews. Nicks in the
body of the capscrew can cause an area of stress that
can fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will damage
the mating parts.
bp8csba
Cleaning
A
Caution: Do not use caustic or acid solutions to clean the
cylinder head capscrews.
\
Use a petroleum-based solvent to clean the capscrews. Dry
with compressed air.
Clean the capscrews thoroughly with a wire brush, a wire
wheel (soft), or use a non-abrasive bead blast to remove
q
deposits from the body and threads.
Cylinder Head Capscrews - Cleaning and inspection for Reuse (l-29)
. . Cylinder Block - GrouD 01
Page l-64 _ 614 Series
Inspection
Visually inspect the cylinder head capscrews for damaged
threads, corroded surfaces, or a reduced diameter (due to
capscrew stretching).
The capscrew must be replaced if:
l The threads are damaged
l Rust or corrosion has caused pitting in the body
l The body is nicked, galled, bent, or stretched
NOTE: The capscrew threads have been formed by a rolling .
operation during manufacture. Repair of rolled threads by the
use of a thread die is not recommended. The thread die can
create a sharp corner on the minor diameter (root) of the
threads. This sharp corner can cause an area of increased
stress.
Do not reuse cylinder head capscrews under the following
conditions:
Visible corrosion or pitting exceeds 1 sq cm [0.155 sq.

inch] in area. Example:
-- Acceptable 3/8x3/8-inch
-- Unacceptable 1/2x1 /2-inch
Visible corrosion or pitting exceeds 0.12 mm [O.O08inch]
in depth.
Visible corrosion or pitting is located within 3.2 mm

[l/&inch] of the fillet.
Visible corrosion or pitting is located within 3.2 mm
[l/&inch] of the threads.
Stretched beyond “free length” maximum. Refer to the
measurement procedure below:
Cylinder Block - Group 01 Engine Lifting Brackets - Cleaning and Inspection for Reuse (l-30)
Free Length - Measurement

Part No. 3823921, Capscrew Length Gauge
NOTE: If the capscrews are not damaged, they can be
reused throughout the life of the engine unless the specified
“free length” is exceeded.
To check the capscrew free length, place the head of the
-
w -L-L
capscrew in the appropriate slot with the flange against the
base of the slot. 4B Flange
Cylinder Head Capscrew Free Length against
mm in Base
.
81.5 Short 3.2
162.6 Long 6.4
04B
If the end of the capscrew touches the foot of the gauge, the
capscrew is too long and must be discarded.
I I i’
IO
Immediately after cleaning and inspecting, apply a film of

clean engine lubricating oil to all capscrews that are to be
used again.
Engine Lifting Brackets - Cleaning and

Inspection for Reuse (I-30)
Use solvent to clean the brackets and capscrews.
q \
0@Y
Visually inspect the engine lifting brackets for cracks, rust
and corrosion.
Cylinder Head - Group 2
614 Series Page 2-1
Cylinder Head - Group 02

Section Contents
Page
Cylinder Head Capscrew - Cleaning and Inspection ................................. 2-37

Cleaning.. ............................................................. 2-37
Inspection ...................................... . ....................... 2-38
Cylinder Head - Cleaning and Inspection for Reuse ................................. 2-9

Cleaning ............................................................... 2-9
Handling .............................................................. 2-9
Inspection .............................................................. 2-10
Cylinder Head - Exploded View ................................................ 2-6
Cylinder Head - General Information ............................................ 2-8
Cylinder Head - Pressure Testing .............................................. 2-34
Cylinder Head - Rebuild ..................................................... 2-l 1

Assembly .............................................................. 2-26
Cleaning ............................................................... 2-12
Disassembly ............................................................ 2-11
Inspection .............................................................. 2-13
Valve - Grinding .......................................................... 2-21
Valve Guide - Inspection .................................................... 2-17
Valve - Inspection ........................................................ 2-20
Valve Seat Insert - Grinding .................................................. 2-22
Valve Seat Insert - inspection ................................................. 2-18
Valve Spring - Inspection ................................................... 2-19
Valve Stem Seal - Inspection ................................................. 2-19
Cylinder Head - Service Tools ................................................. 2-2
Cylinder Head - Vacuum Testing Valve Seating .................................... 236
Cylinder Head - Valve Guide Replacement ........................................ 2-28

Assembly .............................................................. 2-29
Disassembly ............................................................ 2-28
Inspection .............................................................. 2-29
Cylinder Head - Valve Seat Insert Replacement .................................... 231

Inspection .............................................................. 233
Installation ............................................................. 2-33
Removal ............................................................... 231
Free Length - Measurement . . . . . _. . . . . . . . . . . __. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Cylinder Head - Service Tools Cylinder Head - Group 02
Page 2-2 614 Series
Cylinder Head - Service Tools
The following special tools are recommended to perform procedures in Group 02. The use of these tools is
shown in the appropriate procedure. These tools can be purchased from your local Distributor.
Valve Spring Compressor
Used to compress the valve springs to remove the valve

ST-448 collets.
Valve Seat Grinding Machine
Grind the valve seats in the cylinder head. Used with Part No.
ST-885 3823187, Valve Guide Arbor, and various valve seat grinding
stones. Refer to the appropriate grinding stone in this tool list.
Valve Seat Grinding Stone
Grind 15 degree exhaust seats (1.875 inch diameter).

ST-885-l 3
Magnetic Crack Detector
Used to inspect the cylinder head combustion face for cracks

ST-l 166 in the injector bore and valve seat areas. The kit includes Part
No. ST-1 188-7, Powder Spray Bulb, used for spraying the
ST-l 188-8, Metal Powder.
Valve Vacuum Tester
Used with Part No. ST-1257-6, Vacuum Cup. Vacuum test the
ST-l 257 cylinder head to determine if the valves are properly seated.
Valve Seat Extractor
Used to remove exhaust valve seats from the cylinder head.

ST-12761 Used with Part No. 3378817, Slide Hammer.
Cylinder Head - Group 02 Cylinder Head - Service Tools
614 Series Page 2-3
Measure the cylinder head valve spring tension.
Used to remove expansion plugs from the cylinder head.
Valve Facing Machine
Grind cylinder head valves and resurface valve stems.
Valve Seat Grooving Kit
Used with Part No.‘s ST-1276-l and 3377396, Valve Seat

Extractors and Part No. 3376407, cutter, to remove valve seats
from the cylinder head.
Used with Part No.‘s ST-1276-1 and 3377396, Valve Seat

Extractors, to remove valve seats from the cylinder head.
Used to install 3/4 inch expansion plug to the specified depth.
Used with Part No. 3376617, Slide Hammer Assembly, to

remove the intake valve seats from the cylinder head.
Used to ream service valve guides to proper inside diameter

after installation.
Cylinder Head - Service Tools Cylinder Head - Group 02
Page 2-4 614 Series
Used to clean carbon from injector bores.
- Grind 15 degree intake seats (2.250 inch diameter)

- Grind 45 degree exhaust seats (1.875 inch diameter)
Valve Seat Grinding Stone
- Grind 60 degree exhaust seats (1.75 inch diameter)

Valve Seat Grinding Arbor
Used with Part No. ST-685, Valve Seat Grinding Machine, and
various grinding stones for proper alignment during the
grinding operation.
Valve Guide Driver Kit
- Used to install intake valve guides.

- Used to install exhaust valve guides.
- Used to remove intake and exhaust valve guides.
Used to measure the injector protrusion and valve recess in

the cylinder head.
Used to install 1 3/16 inch expansion plug to the specified
Used to install 2-l/4 inch expansion plug to the specified

Cylinder Head - Group 02 Cylinder Head - Service Tools
614 Series Page 2-5
Capscrew Length Gauge
Used to check cylinder head capscrew free length.

3623921
Cylinder Head - Exploded View Cylinder Head - Group 02
Page 2-6 614 Series
Cylinder Head - Exploded View
9 -25
-18
Cylinder Head - Group 02 Cylinder Head - Exploded View
614 Series Page 2-7
Ref. No Part Name QW

1 Head, Cylinder 1
2 Plug, Expansion 1
3 Plug, Expansion 5
3 Plug, Expansion 1
4 Plug, Expansion 2
5 Guide, Valve Stem 12
6 Insert, Valve Seat (Exh) 6
7 Insert, Valve Seat (lnt) 6
8 Plug, Pipe 1
9 Plug, Pipe 1
10 Plug, Pipe 1
11 Seal, Valve Stem (Int) 6
12 Valve, Intake 6
13 Collet, Valve 24
14 Valve, Exhaust 6
15 Washer, Sealing 2
16 Plug, Pipe 2
17 Spring, Valve (lnt) 6
18 Spring, Valve (Exh) 6
19 Retainer, Valve Spring 12
20 Seal, Valve Stem (Exh) 6
21 Plug, Expansion 1
22 Coupling, Elbow 1
23 Gasket, Cylinder Head 1
24 Screw, Hex Hd Cap (Flange) 12

25 Screw, Hex Hd. Cap (Flange) 14
Cylinder Head - General Information Cylinder Head - Group 02
Page 2-8 614 Series
Cylinder Head - General Information

The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, valve stem seals, valve seat
inserts, cylinder head capscrews, collets and spring retainers.
The cylinder head is a one piece, crossflow design with two valves per cylinder. The valve guides and seats are
replaceable. The cylinder head has a cast intake manifold and fuel filter head. The injectors are mounted in the cylinder
head for direct injection of fuel into the cylinders.
The cylinder head gasket is a laminated design with a fire ring to seal the cylinder bores. Orifices in the gasket control
coolant flow. Thicker gaskets are available for cylinder blocks that have been resurfaced 0.25 mm [O.OlO inch] or more.
NOTE: Engines equipped with an exhaust brake that impose from 241 to 448 kPa 135 to 65 psi] exhaust back pressure
must use dual exhaust valve springs.
Mark, label, or tag the cylinder head parts such as valves and valve springs with the cylinder number and location from
which they were removed. This practice will prove to be a valuable aid in diagnosing any cylinder head or part failures
and to make sure the reuseable parts are installed in their original locations.
Cylinder Head - Group 02 Cylinder Head - Cleaning and Inspection for Reuse (2-01)
614 Series Page 2-9
Cylinder Head - Cleaning and Inspection

for Reuse (2-01)
Handling
The component weighs 23 kg 150 lb] or more. To avoid
component.
Use a hoist or hydraulic arm to lift the cylinder head.
NOTE: Place the cylinder head on wood blocks to prevent
damage to the combustion surface.
Cleaning
Remove the gasket material from the valve cover surface.
Use a gasket scraper to remove the heavy dirt and debris
from the cylinder head gasket surface and exhaust manifold
gasket surface.

A
Use steam to clean the cylinder head. Dry with compressed
air.
Caution: When using compressed air to clean capscrew
holes, always wear safety glasses or a face shield to
protect the eyes. Personal injury can result. A
kn900ea
Use Scotch-Brite@ 7448, Part No. 3823258 or equivalent, to

clean the cylinder head combustion surface and exhaust
manifold gasket surface.
kn9OOeb
Cylinder Head - Cleaning and Inspection for Reuse (2-01) Cylinder Head - Group 02
Page 2-10 614 S&es
Clean the cylinder head with solvent.
Inspection
04B
Visually inspect the cylinder head for obvious damage that
would prohibit reuse. Check for cracks and damage to the
combustion surface that would result in loss of sealing.
If cracks or leaks in the cylinder head are suspected, refer to
Cylinder Head - Pressure Testing (2-05).
oonoo
0
Visually inspect the valves and valve springs for cracks, bent or
683 broken valve stems, broken valve spring collets or other
damage.
Visually inspect the valves for indications of leakage or burning.
If cracked or damaged parts, or indication of leakage or
burning is found, the cylinder head must be rebuilt. Refer to
Cylinder Head - Rebuild (2-02).
Valve and Seat - Leakage Testing

NOTE: If a leaking valve is suspected, vacuum test the valves
and valve seats. The vacuum must not drop more than 25.4
mm Hg [l.O inch Hg] in 5 seconds.
Valve to Valve Seat Vacuum

mm Hg in Hg
457 used 18
635 New 25
kn900kb
Cylinder Head - Group 02 Cylinder Head - Rebuild (2-02)
614 Series Page 2-l1
NOTE: If vacuum does not meet the specifications, the face

of the valves and the valve seat inserts must be resurfaced.
Refer to Procedure 2-02.
Cylinder Head - Rebuild (2-02)

Disassembly
Part No. ST-583, Cylinder Head Holding Fixture
Install the cylinder head in the Part No. ST-583, Head
Holding Fixture, as shown.
kn9toha
NOTE: Before removing the valves, use paint or Dykemm to

identify the location of the valves and retainers. If the parts
are used again, they must be installed in their original
locations.
I kn9vawa
Part No. ST-448, Valve Spring Compressor

Place a wood block between the valves and head holding
fixture to support the valves.
Use the valve spring compressor to compress the valve
springs.
Cylinder Head - Rebuild (2-02) Cylinder Head - Group 02
Use a pencil magnet to remove the valve collets. Discard the

valve collets.
Slowly release the pressure on the valve spring.
Remove the valve spring retainer.

Remove the valve spring.
Remove the valve.
Remove the valve spring seat/valve seal assembly.
Keep the valves in a labeled rack.
kn2vaga
Cleaning
q
B Scrape the gasket material from all gasket surfaces.
q
Clean the cylinder head combustion surface with a
Scotch-BriteQ 7448 pad, or an equivalent cleaning pad and \
solvent.
Inspection
Straight Edge and Feeler Gauge
Use a straight edge and feeler gauge to check the cylinder E2l
0@3
head combustion surface for flatness.
Cylinder Head Flatness Specifications

mm in
0.20 End-to-End 0.008 @
0.076 Side-to-Side 0.003
Use a small 51 mm [2.0 inch] straight edge and a 0.001 inch

feeler gauge to measure local cylinder head combustion
surface flatness. Check between the cylinder bores and also
between the coolant passages. If the 0.001 inch feeler gauge
fiis under the 2.0 inch straight edge or if the cylinder head is
pitted, has grooves or wear greater than the maximum
specified, the cylinder head must be replaced or resurfaced.
NOTE: A maximum of 1.00 mm [0.040 in] can be machined

from the combustion surface of the cylinder head.
If the cylinder head is machined, place the valve in the
respective bore and check the valve depth dimension. If the
depth is less than the minimum specification, the valve seat
will require machining. Refer to Valve Seat - Grinding in this
section.
Install an injector with an injector seal to check for proper
injector tip protrusion.
Measure the cylinder head thickness.
Cylinder Head Thickness (New)

mm in
115.75 MIN 4.557
116.25 MAX 4.577
Replace the cylinder head if the thickness is less than 114.75

mm [4.518 inch].
kn900na
Part No. 3822510, Injector Bore Brush

El If the cylinder head flatness and thickness
specifications, continue with the cleaning operation.
is within
\
q Clean the carbon from the cylinder head injector bore.
Expansion Plug - Removal

Clean the build-up of deposits from the coolant passages.
Excessive deposits may be cleaned in an acid tank but the
expansion plugs must first be removed.
Use a center punch to mark the expansion plugs for drilling.
Drill a l/8 inch hole in the expansion plugs.
69 l Use a dent puller to remove the expansion

Remove the pipe plugs.
plugs.
knsepma
Warning: Wear protective eye covering.

A Clean carbon deposits from the valve pockets with a high
q
quality steel wire wheel installed in a drill or a die grinder.
B NOTE: An inferior quality wire wheel will loose steel bristles
during operation, thus causing additional contamination.
Place the cylinder head and parts in a tank of cleaning

solution.
NOTE: Be sure to follow the cleaning solution manufacturer’s
instructions when cleaning the parts.
kn900ed
Remove the cylinder head and parts from the cleaning tank.
Visually inspect all passages to make sure they are clean.
Use Scotch-Brite@ 7448, Part No. 3823258 or equivalent, to

clean the cylinder ‘head combustion surface and the exhaust
manifold gasket surface.
q
lb
kn900eb
Use the Part No. ST-1 166, Magnetic Crack Detector, to find
cracks in the combustion surface and areas around the valve
ports and injector bores.
Place the magnetizing head on the combustion surface as
shown, to check for cracks that run across the cylinder
head.
0
@
0
Fill the magnetic crack detector powder spray bulb one-third
a3 (l/3) full with metal powder.
Spray the powder lightly onto the combustion surface.
Use compressed air to remove the excess metal powder.
Air Pressure: 276 kPa [40 psi]
NOTE: The powder will remain in the cracks, if present, and
show as a white line.
0
Check for cracks on the combustion surface. Cracks that
43 extend from the injector bore away from the valve seats and
are not over 10 mm [0.394 inch] long are acceptable.
A = 10 mm [0.394 inch]
knSbdsa
0
Any cracks that extend from the injector bore toward the valve
a3 seats are unacceptable and the cylinder head must be
replaced.
knsbdsd
0
Cracks between the valve seats are not acceptable and the
+B cylinder head must be replaced.
knsbdsc
0@
Place the magnetizing head on the combustion surface as
shown to check for cracks that run lengthwise of the cylinder
head.
Repeat the procedure as outlined above.
q
Remove all magnetism and use solvent to clean the cylinder
head. Dry with compressed air. \
NOTE: The cylinder head must be thoroughly cleaned after
using the magnetic crack detector to remove all of the metal
powder.
Valve Guide - Inspection

Visually inspect the valve guides for scuffing or scoring.
Use a small bore gauge to measure the inside diameter of
the valve guides in locations 13 mm [l/2 inch] from each
0@
end and at the center as shown.
Valve Guide I.D. (Installed) (Used)

mm in
9.539 MIN 0.3756
9.591 MAX 0.3776
Use a depth micrometer to measure the valve guide installed

height. Measure from the top of the valve guide to the
bottom of the recess area.
Valve Guide Height (Installed)

mm in
Intake 20.65 MIN 0.813
21.16 MAX 0.833
Exhaust 22.50 MIN 0.886
23.01 MAX 0.906
If damage is found or the valve guide(s) do not meet the &a

limits specified, the valve guide(s) must be replaced. Refer to
Procedure 2-03.
Valve Seat Insert - Inspection
06B Visually
spots.
inspect the valve seat inserts for cracks or burned
r-J-- I kn9OOkf
Measure the width of the valve seat area (1) of the valve seat
inserts.
Valve Seat Area (Width)

mm in
1.5 MIN 0.059
2.0 MAX 0.079
NOTE: The sealing surface of the valve should seat in the

center of the valve seat insert.
If the valve seat area is worn wider than the maximum
specified, refer to Valve Seat - Grinding or Cylinder Head -
Valve Seat Insert Replacement, in this section.
Part No. 3823495 Gauge Block

Install the valves in their respective bores and measure the
recess in the cylinder head.
Make sure the seats are clean before measuring the recess.
Valve Recess in Cylinder Head

mm in
1.09 MIN 0.043
1.62 MAX 0.064
NOTE: If the valve recess is out-of-limits, before replacing the

valve seat, try replacing the old valve (A) with a new valve (B).
If the recess is within limits with the new valve, grind the old
valve seat and use the new valve. Refer to Valve Seat -
Grinding in this section.
knSvana
Valve Spring - Inspection

Inspect the valve springs for obvious damage (breaks, etc.).
0
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Measure the valve spring.
Valve Spring Free Height (A)

mm in
66.66 Nominal 2.586
I”““‘I”~‘“‘l’“‘“‘l”““‘l”““‘1’““”
Use the Part No, 3375182, Valve Spring Tester, to measure

the valve spring load at the opening height.
Valve Spring Opening Height (B)

mm in
37.96 Nominal 1.492
Valve Spring Load for Opening Height ( New)(C)

N Ibf
980 MIN 216
1060 MAX 238
If the valve spring load for the opening height is less than
the minimum specified, the valve spring must be replaced.
Valve Stem Seal - Inspection
Visually inspect the valve spring retainers and valve stem
seals for damaged or worn areas.
Remove the valve stem seals from the valve stem seal
retainers, and visually inspect for damaged or worn areas.
Discard unserviceable parts.
Valve - Inspection
04B Visually inspect the valves for damage. Replace the valves if
any of the following conditions are found:
l Valve stems worn below specifications (A)
l Rust or pitting on the valve stem or sealing surface
(B)
l Worn collet grooves (C)
kn9vakb
l Worn stem tip (D)

l Bent valve stems (E)
l Damaged valve heads (burned, cracked or broken) (F)
Measure the outside diameter of the valve stem.
Valve Stem O.D.

mm in
9.46 MIN 0.372
9.50 MAX 0.374
2.5 In.4
0
NOTE: It may be possible to grind and reuse valves with the
a!3 following conditions:
l Minor grooves on the valve sealing surface (A)
l Fine pitting on the valve sealing surface (B)
l Carbon or varnish buildup on the valve stem (C)
Valve - Grinding
Cleaning
NOTE: Any valves that are to be used again must have the
sealing surface machined.
Use Scotch-B&?@ 7448, Part No. 3823258, to clean the valve
stems. Clean the carbon deposits from the valve sealing
surface and head.
NOTE: The valves must be clean and free of carbon
deposits before they are refaced. Valves can be cleaned by
the bead blasting method in the head area only.
knlvaec
Use a valve facing machine, Part No. 3376256, to grind the

sealing surface of the valve.
NOTE: Follow the instructions supplied with the valve
grinding machine for the correct setup before grinding the e
valves.
Grind the intake and exhaust valves to the angle shown

below:
Intake
Exhaust
Valve
Valve Seat Angle
30 Degrees
45 Degrees
Angle
Use solvent to clean the metal particles from the valve. Dry
q
\
Ld3o”
‘>\
Put the valve on a flat surface and measure the head

thickness (1) at the outside diameter.
Valve Head Thickness (at O.D.)

mm in
1.5 MIN 0.059
NOTE: If the valve head is worn thinner than the minimum

specified, the valve(s) must be replaced.
Use a lead pencil or Dykem to mark across the valve sealing

surface as shown. Install the valve in the valve guide.
Hold the valve against the valve seat, and rotate the valve
backward and forward three or four times. Correct contact
against the valve seat will break the pencil marks on the valve
sealing surface.
NOTE: Valves and valve seats that are correctly machined do
not require the use of lapping compound to make an air tight
seal. If lapping compound is required, inspect the adjustments
of the grinding machine and the condition of the grinding
stone.
Install the valves in the cylinder head. Refer to “Assembly”

under Cylinder Head - Rebuild.
Use valve vacuum tester, Part No. ST-1257, to vacuum test the
valve seating. Refer to Cylinder Head - Vacuum Testing Valve
Seating 2-06.
kn900kb
Valve Seat Insert - Grinding

NOTE: If the valve guide inside diameter exceeds the maximum
worn limit, replace the valve guide before grinding the valve
seat.
Use the Part No. ST-686 Valve Seat Grinding Machine and the
Part No. 3823187, Valve Guide Arbor Set, when grinding the
valve seat inserts.
Install the valve guide arbor (1) in the valve guide with the
arbor puller (2).
Rotate the arbor to be sure that it is installed correctly.
Install a valve seat grinding stone (3) on the grinding machine.

NOTE: The grinding stone must be the correct size and have
the correct angle (Intake: 30 Degrees, Exhaust: 46 Degrees).
Refer to the Service Tool List in the front of this section.
Install the grinding machine on the arbor.
NOTE: The grinding stone (3) must not touch the valve seat
insert when the drive unit motor is started.
Hold the drive unit in a vertical position, and use an
up-and-down movement of 12.7 mm [0.50-inch] travel and light
pressure to grind the seat.
Remove the grinding machine from the arbor.
Install eccentrimeter gauge (4), Part No. ST-665-4, on the @

valve guide arbor.
@
Measure the valve seat to valve guide concentricity.
Concentricity (Per 360 Degrees)

mm in
0.05 MAX 0.002
NOTE: If the valve seat concentricity does not meet the

specifications, grind the valve seat again. If the specifications e
cannot be met, replace the valve seat insert. Refer to
Cylinder Head - Valve Seat Insert Replacement (02-04).
Install reconditioned valves in their respective bores. Hold the @@A

valve firmly against the valve seat insert.
@
Part No. 3823495,. Gauge Block

Measure the valve recess in the head.
Valve Recess in Cylinder Head

mm in
1.09 MIN 0.043
1.62 MAX 0.064
knlvatg
if the valve recess is out of limits, replace the old valve (A)
with a new valve (B) before replacing the valve seat. If the
recess is within limits with the new valve, proceed by using
the new valve with the old seat.
If the valve recess is still out of limits, even with the new valve
(B), replace valve seat (C) with a new valve seat (D). After
replacing the seat, check the valve recess again with the old
valve (A) to determine if it can be reused. If not, proceed by
using the new valve (B).
(A) = Old Valve
(B) = New Valve
(C) = Old Valve Seat Insert
(D) = New Valve Seat Insert
0
1
Check the valve seat contact area on the valve sealing surface
83 to see if the valve seat contacts the center of the valve sealing
surface.
Use a pencil or Dykem@ to put vertical marks on the sealing
surface of the valve.
knlvase
Install the valve in the valve guide. Hold the valve against the
valve seat insert.
Rotate the valve backward and forward three or four times.
Remove the valve and measure the valve seat width and the
seat contact area as indicated by the broken pencil lines.
The pencil or Dykem@ marks will be worn away where the

valve contacted the seat.
Valve Seat Width Limit

mm in
1.5 MIN 0.059
2.0 MAX 0.079
Grind valve seat insert area (A) with a 60degree stone and
valve seat insert area (B) with a 15degree stone to center
the seat on the valve sealing surface and to obtain the valve
seat width limits.
I knlvaxa
The location of the broken pencil lines on the valve sealing

surface is the key to determining how much of each valve
seat insert angle to grind.
If the broken lines are at the bottom of the valve sealing
surface, the valve seat insert will require more grinding with
the 60-degree stone than with the 15degree stone.
If the broken lines are at the top of the valve sealing surface,
the valve seat insert will require more grinding with the
15degree stone than with the 60degree stone.
kn8vaxd
After grinding the valve seat inserts, use a bristle brush to

clean the inside diameter of the valve guides.
Use solvent to clean the cylinder head. Dry with compressed m
air.
Assembly
Expansion Plug Installation
Apply cup plug sealant, Part No. 3375068, to the outside
diameter of the expansion plugs.
NOTE: Use the correct expansion plug driver to make sure the
expansion plugs are installed to the correct depth in the
cylinder head. Drive the plug until the shoulder of the driver
contacts the cylinder head. Refer to the chart below:
Tool P/N Exp. Plug P/N Qty. Location
3823522 156075 1 A
3823524 3900965 2 B
3823522 3032693 5 C
3376815 3912900 1 D
NOTE: If the engine is equipped with an air compressor,

expansion plug (D) is not used. A 90degree elbow coupling is
knsephb
installed in this hole for the air compressor air inlet. Apply Part
No. 3375068, Cup Plug Sealant, and install the fitting with the
beaded end pointing down to the 4:00 o’clock position.
Pipe Plug Installation

If the pipe plugs are not already precoated, apply a coat of
Part No. 3375068, Cup Plug Sealant, to the pipe plug threads.
Install the pipe plugs, refer to the following chart:
Torque Value:
Location Size Nom Ft-lb
A l/16 in. NPT 8 71 in-lb
B l/4 in. NPT 12 106 in-lb
C l/2 in. NPT 24 18 ft-lb
D Hex Plug 80 59 ft-lb
NOTE: The hex plugs (D) require a copper sealing washer.
Use a bristle brush to clean the inside diameter of the valve

guide bores and blow out with compressed air.
Use SAE SOW engine oil to lubricate the valve guide bores
and valve stems, \
LJ
Install the valves in the valve guides. The exhaust valves
have smaller diameter heads.
NOTE: If any valves are being used again, the valves must
be installed in the same location as they were removed.
NOTE: The valves should drop into the valve guides with
little or no resistance.
After the valves are installed, place the cylinder head on a
flat surface that will not damage the cylinder head surface.
Install the valve spring seat/valve seal assembly over the

valve stem.
NOTE: To prevent oil carryover, the seals are color coded
and must be installed as follows:
Exhaust Valve (A): Orange (with 64 grooves per inch)
Intake Valve (B): Black (with 40 grooves per inch)
Install the valve springs.

Install the valve spring retainers.
Use valve spring compressor, Part No. ST-448, or its

equivalent (refer to the Service Tools list) to compress the
valve springs.
Install the new valve spring retainer collets.
NOTE: Use new valve spring retainer collets when rebuilding
the cylinder head.
Cylinder Head - Valve Guide Replacement (2-03) Cylinder Head - Group 02
A Warning: Wear eye protection. If the collets are not correctly

installed, they can fly out when the stems are hit with a
hammer.
Use a plastic hammer to gently hit the top of the valve stems
to make sure the valve collets are correctly seated in the spring
retainer.
Use valve vacuum tester, Part No. ST-1257, to vacuum test the
valve seating. Refer to Cylinder Head - Vacuum Testing Valve
Seating (2-06).
Y kn900kb
Cylinder Head - Valve Guide

Replacement (2-03)
Disassembly
NOTE: It will be necessary to grind the valve seats after
replacing the valve guides. Refer to Procedure 2-02 in this
section.
Use the Part No. 3823271, Valve Guide Driver (l), to remove
the old valve guides (2).
knsguma
Use a flexible brush and solvent to clean the valve guide bores
in the cylinder head. Dry with compressed air.
Cylinder Head - Group 02 Cylinder Head - Valve Guide Replacement (2-03)
Inspection
Measure the inside diameter of the valve guide bore in the
cylinder head.
Valve Guide Bore I.D.

mm in
15.931 MIN 0.6272
15.971 MAX 0.6266
If the valve guide bore is worn larger than the maximum
specified, the cylinder head must be replaced.
Assembly
Measure the outside diameter of the new valve guides.
Valve Guide O.D.

mm in
15.988 MIN 0.6294
16.000 MAX 0.6299
I knlguth
The intake and exhaust valve guides are installed at

heights above the cylinder head top deck surface,
the following part numbers for the correct installation
Intake: Part No. 3823269
Exhaust: Part No. 3823270
Drive the valve guides into the cylinder head valve guide
bore until the driver contacts the cylinder head.
Use a depth micrometer to measure the new valve guide

installed height above the cylinder head top deck surface.
Valve Guide Height (Installed)

mm in
Intake: 20.65 MIN 0.813
21.16 MAX 0.833
Exhaust 22.50 MIN 0.886
23.01 MAX 0.906
Cylinder Head - Valve Guide Replacement (2-03) Cylinder Head - Group 02
Currently there are no replaceable service valve guides

available. It will be necessary to install standard valve guides
and machine the inside diameter to within 0.254 mm [O.OlO
inch] of the new specification listed on the following page and
use a hand reamer to finish reaming the valve guide inside
diameter.
Part No. 3822490, Valve Guide Reamer

Ream the valve guides with no lubricant and in one direction
only. Damage to the guide can result from pulling the reamer
back through the guide.
I A Ilxl Lubricate the reamer with clean 15W-40 engine oil and ream
I .jqy the valve guide again in one direction only.
Clean the valve guide bore with a nylon bristle brush and
cleaning solvent.
Cylinder Head - Group 02 Cylinder Head - Valve Seat Insert Replacement (2-04)
Use a small bore gauge to measure the new valve guide

inside diameter in locations (1) 13 mm [l/2 inch] from each
end and at the center as shown.
(New) Valve Guide I.D. (Installed)

mm in
9.539 MIN 0.3756
9.559 MAX 0.3763
If the valve guide is not within the specifications given, the
valve guide must be removed and a new valve guide
installed.
Cylinder Head - Valve Seat Insert

Replacement (2-04)
Removal
NOTE: If it is determined that both valve seats and valve
guides need to be replaced, install and ream the valve
guides first.
c%
0
kn9isma
Part No. 3376405,. Router; Part No. 3376407, Cutter

Adjust the cutter depth to approximately 1.4 mm [0.055 inch]
from the bottom of the valve seat pocket.
Eil
Cut a groove in the valve seats. Be sure the cutter motor

base remains flat against the cylinder head while rotating the
cutter motor in a circular motion.
Cylinder Head - Valve Seat insert Replacement (2-04) Cylinder Head - Group 02
A Caution: Shavinas or debris between the cutter motor base

and the head d&k can cause serious damage.
Cut a groove deep enough for the expanding seat extractor

tool to engage when expanded.
0@3
Make sure the tool cuts only the valve seat inserts and not into
the machined valve pockets of the cylinder head.
kn9toxd
Part No. 3376617, Slide Hammer

Part No. 3377396, Intake Seat Extractor
Part No. ST-1276-1, Exhaust Seat Extractor
Remove the valve seat inserts.
Cylinder Head - Group 02 Cylinder Head - Valve Seat Insert Replacement (2-04)
Use a wire brush and solvent to clean the deposits from the
valve seat insert bores.
Use solvent to clean the cylinder head. Dry with compressed
air.
Inspection
Visually inspect
damage.
If cracks
the valve
or damage
seat insert
is found,
bore for
the cylinder
cracks
head must be
or
0a9
replaced.
Measure the inside diameter of the valve seat insert bore (A)
and the valve seat’insert bore depth (B) in the cylinder head.
(A) Insert Bore I.D. (Standard Insert)

mm in
Intake 53.93 MAX 2.123
Exhaust 47.03 MAX 1.882
(B) Insert Bore Depth (Standard Insert)

mm in
Intake 12.20 MAX 0.480
Exhaust 9.83 MAX 0.387
NOTE: If either dimension is out of specifications, the
cylinder head must be replaced.
Installation
For easier installation, freeze the new valve seat inserts at
18°C [OOF] for 30 minutes before attempting to install.
Remove the valve seat inserts from the freezer one at a time.
kn900hb
Cylinder Head - Pressure Testing (2-05) Cylinder Head - Group 02
NOTE: The valve seat insert chamfer (1) must be installed

toward the bottom of the counterbore.
Use the Part No. 3376617, Slide Hammer, and a suitable driver,
refer to Cylinder Head - Service Tools, to drive the valve seat
insert into the counterbore.
Make sure the insert is at the bottom of the counterbore.
Use the Part No. ST-685, Valve Seat Grinding Machine, and
Part No. 3823187, Valve Guide Arbor and the appropriate
grinding stone (3), to grind the new valve seat inserts. Refer to
Valve Seat - Grinding in this section.
Cylinder Head - Pressure Testing (2-05)
A
Caution: Do not pressure test the cylinder head with the
valves and valve springs installed. Water entering the
cylinder head cannot be dried thoroughly and will damage
the valve guides and valve stems. Refer to Cylinder Head
- Disassembly (2-02).
E-3 I I// I lr kn9spmb
NOTE: A cylinder head test fixture can be fabricated from a flat

piece of steel or aluminum. Refer to the following table for test
fixture dimensions:
Test Fixture Dimensions

mm in
851 Length 33.5
190 Width 7.5
16 Thickness 0.625
NOTE: Use the cylinder head gasket as a pattern for drilling
the capscrew holes.
kn9gknt
Cylinder Head - Group 02 Cylinder Head - Pressure Testing (2-05)
Install the cylinder head water test fixture.

Install a new head gasket.
Install the test plate.
install the 26 cylinder head capscrews and Ml4 X 2.0 nuts.
Tighten the nuts.
Connect a regulated air supply hose to the text fixture plate.

Apply air pressure.
Use a nylon lifting strap and hoist to place the cylinder head
in a tank of heated water.
Temperature: 60” C [ 140” F]
Completely submerge the cylinder head in the water.
276 kPa
140 PSI]
kn9OOkd
Visually inspect for air bubbles rising from the water.

If air bubbles are seen, replace or rebuild the cylinder head.
Refer to Procedure (2-02).
kn9OOks
Remove the test equipment.

Use compressed air to dry the cylinder head.
Assemble the cylinder head. Refer to Cylinder Head - Rebuild
- Assembly (2-02).
;;;lh&T;iead - Vacuum Testing Valve Seating (2-06) Cylinder Head - Group 02
614 Series
Cylinder Head - Vacuum Testing Valve

Seating (2-06)
Use the Part No. ST-1257, Valve Vacuum Tester, to inspect the
seal between the valve and the valve seat insert.
NOTE: The valve vacuum tester can be used to test all KDC
engine models. The Part No. S-T-1257-6, Vacuum Cup, is used
on the 614 Series cylinder heads.
kn900kb
Install the seal ring and vacuum cup to the vacuum line (hose).
kn2toaa
The valves and valve seat inserts must be clean and dry when
vacuum testing.
Cover the valve with the cup and seal.
NOTE: The seal must make a tight contact on the cylinder
head around the valve.
Move the toggle switch (1) to the “ON” position.

Turn the vacuum control valve (2) to the “OPEN” position.
NOTE: The vacuum control valve is in the “OPEN” position if
the vacuum gauge needle moves clockwise.
Cylinder Head - Group 02 Cylinder Head Capscrew - Cleaning and Inspection (2-07)
Operate the vacuum pump until the gauge indicates the

specified vacuum.
Valve to Valve Seat Vacuum

mm Hg in Hg
New 508 MIN 20
635 MAX 25
used 457 MIN 18
Turn the toggle switch (1) to the “OFF” position.
Use a stopwatch and start timing when the needle on the

gauge indicates 457 mm Hg [18 in. Hg].
Stop timing when the needle on the gauge indicates 203 mm
Hg [8 in. Hg].
The elapsed time for the needle to move between the
specified gauge readings must be 10 seconds or more.
06iB
If the elapsed times is less than 10 seconds, perform the
following checks:
l Repeat the test to be sure the equipment is operating
properly.
l Use a mallet to hit the valve stem lightly to make sure
the valve is seated. Repeat the test.
l Apply a thin layer of grease on the outside diameters
of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.
A break in the grease seal pattern will indicate leakage e
between the valves and valve seat or the valve seat insert
kn900kb
and the cylinder head. Refer to Cylinder Head - Rebuild.
Cylinder Head Capscrew - Cleaning and

Inspection (2-07)
Cleaning
Caution: Do not use caustic
cylinder head capscrews.
or acid solutions to clean the
A
Use a petroleum-based solvent to clean the capscrews.
Clean the capscrews thoroughly with a wire brush, a soft
wire wheel, or use a non-abrasive bead blast to remove
deposits from the shank and the threads.
Cylinder Head Capscrew - Cleaning and Inspection (2-07) Cylinder Head - Group 02
Page 2-38 614 Skies
Inspection
04lP Visually inspect the cylinder head capscrews for damaged

threads, corroded surfaces, or a reduced diameter (due to
capscrew stretching).
NOTE: Do not reuse a capscrew that has damaged threads or
a reduced diameter from having been stretched.
Do not reuse cylinder head capscrews under the following

conditions:
l Visible corrosion or pitting exceeds 1 sqcm [0.155 sq.
inch] in area. Example:
- Acceptable 318-x 3/8-inch
- Unacceptable 1/2-x 1/e-inch
l Visible corrosion or pitting exceeds 0.12 mm
[0.005-inch] in depth.
l Visible corrosion or pitting is located within 3.2 mm

[l/&inch] of the fillet.
l Visible corrosion or pitting is located within 3.2 mm
[l/8-inch] of the threads.
l Stretched beyond “free length” maximum. Refer to the
measurement procedure below:
Cylinder Head - Group 02 Cylinder Head Capscrew - Cleaning and Inspection (2-07)
Free Length - Measurement

Part No. 3823921, Capscrew Length Gauge
If the capscrews are not damaged, they can be reused
throughout the life of the engine unless the specified “free
length” is exceeded.
To check the capscrew free length, place the head of the
capscrew in the appropriate slot with the flange against the
base of the slot.
-I
L
-I-
Flange
Capscrew Free Length against
in Base
mm
k”W%
81.5 Short 3.2
162.6 Long 6.4
06i-3
If the end of the capscrew touches the foot of the gauge, the
capscrew is too long and must be discarded. Contact -<+
The capscrew can be used again if there is clearance
between the end of the capscrew and the bottom base of
the tool. I
Immediately after -cleaning and inspecting, apply a film of

used again.
Immediately after cleaning and inspecting, apply a film of
used again.
Rocker Levers - Group 03
614 Series Page 3-l
Rocker Levers - Group 03

Section Contents
Page
Crankcase Breather Tube - Cleaning and Inspection for Reuse ......................... 3-6
Cleaning and Inspection .................................................... 3-6
Rocker Assembly Oil Manifold - Cleaning and Inspection for Reuse ...................... 3-7
Cleaning ............................................................... 3-7
Inspection .............................................................. 3-7
Rocker Lever Assembly - Cleaning and Inspection .................................. 3-4

Assembly .............................................................. 3-6
Cleaning ............................................................... 36
Disassembly ............................................................ 3-4
Inspection .............................................................. 3-5
Rocker Lever Assembly - Exploded View ......................................... 3-2
Rocker Lever Assembly - General Information ..................................... 3-3
Valve Cover - Cleaning and Inspection for Reuse ................................... 3-6

Cleaning ............................................................... 38
Inspection .............................................................. 3-6
Rocker Lever Assembly - Exploded View Rocker Levers - Group 03
Page 3-2 614 Series
Rocker Lever Assembly - Exploded View
Ref. No. Part Name QtY.

1 Screw, Twelve Point 12
2 Clamp, Rocker Retainer 6
3 Rod, Push 12
4 Support, Rocker Lever 6
5 Lever, Rocker 2
6 Nut 2
7 Screw, Rocker Adjusting 2
8 Washer, Curved Spring 2
9 Shaft, Rocker 1
10 Plug, Expansion 2
11 Washer, Thrust 2
12 Manifold, Oil 1
13 Ring, Retaining 2
Rocker Levers - Group 03 Rocker Lever Assembly - General Information
614 Series Page 3-3
Rocker Lever Assembly - General Information

The rocker lever group consists of the rocker lever assemblies, rocker assembly oil manifold, valve cover and crankcase
breather.
Each cylinder of the engine has a separate rocker lever assembly. The pedestal support has drillings to route the oil flow
to the shaft and levers.
The rocker levers are push rod actuated and use an adjusting screw to control the clearance between the rocker lever
and valve stem. The rocker levers do not use a bushing in the bore for the rocker lever shaft. The rocker lever must be
replaced if the bore is damaged or worn beyond the specification limit.
Rocker Lever Assembly - Cleaning and Inspection (3-01) Rocker Levers - Grow 03
Page 3-4 614 S&ies
Rocker Lever Assembly - Cleaning and

Inspection (3-01)
Disassembly
Snap Ring Pliers
RI Remove the retaining rings, thrust washers and wavey spring
washers.
69
l
Remove the rocker levers.

69
l
rh$OOfb
Remove the pedestal assembly.

6s
0
I rh900ha
Remove the locknut and adjusting screw.
rh9OOfc
Rocker Levers - Group 03 Rocker Lever Assembly - Cleaning and Inspection (3-01)
614 Series Page 3-5
-I
Cleaning
Clean all parts in strong solution
water.
of laundry detergent in hot
\
q
rh900ea
Use compressed air to dry the parts after rinsing in clean hot
water.
rh900eb
Inspection
Inspect for cracks and excessive wear in the bore and the
contact surface for the valve stem.
NOTE: The levers do not use a bushing in the bore for the
0a!3
rocker lever shaft. The lever must be replaced if the bore is
damaged or worn beyond the specification.
Measure the rocker lever bore.
Rocker Lever Bore Diameter

mm in.
22.256 MIN 0.8762
22.301 MAX 0.878
rh9brta
Rocker Lever Assembly - Cleaning and Inspection (3-01) Rocker Levers - Group 03
Page 3-6 614 Series
Visually inspect the rocker lever shafts for pitting, scoring or

other damage.
Measure the rocker lever shaft diameter.
Rocker Lever Shaft Diameter

mm in.
22.199 MIN 0.874
22.231 MAX 0.8752
bpSOOsa
Assembly
Install the adjusting screw and locknut.
rh900fc
Install a retaining ring, thrust washer and wavey spring washer

as illustrated.
rhSOOaa
Lubricate the shaft with engine oil.

Rocker Levers - Group 03 Valve Cover - Cleaning and Inspection for Reuse (3-03)
614 Series Page 3-7
Position the levers on the rocker shaft.
rh9OOab
Install the remaining wavey spring washer, thrust washer and @

retaining ring as illustrated.
G!sY
rh900ac
Compress the wavey spring washers and install the bottom @?,
half of the pedestal as illustrated.
4x9
rh900ad
Rocker Assembly Oil Manifold - Cleaning

. and Inspection for Reuse (3-02)
Cleaning
q
Use solvent to clean the oil manifold. Dry with compressed
air. \
Inspection
Visually inspect the oil manifold for cracks, plugged oil holes,
or other damage. If the oil manifold is cracked or damaged, &!!!
4~
It must be replaced.
Valve Cover - Cleaning and Inspection for Reuse (3-03)
. . Rocker Levers - Group 03
Page 3-8 614 Series
Valve Cover - Cleaning and Inspection

for Reuse (3-03)
Cleaning
0a3 Inspect the valve cover seal for damage.

NOTE: The seal can be reused if it is not damaged.
q
\ Steam clean and dry with compressed air.
Inspection
Visually inspect the valve cover for cracks or damage and
replace if necessary.
NOTE: If the seal is not damaged, it can be used again.

If the seal is damaged, install a new seal.
Install the seal into the groove in the valve cover. Start the
installation at the overlap area shown in the illustration. Do not
stretch the rubber seal.
If the seal has more overlap than shown in the illustration, trim
the length to provide the correct overlap.
Crankcase Breather Tube - Cleaning and

Inspection for Reuse (3-04)
Cleaning and Inspection
Use solvent to clean the hose and tube. Dry with compressed
air.
Visualy inspect the hose and tube for restrictions, cracks or
other damage. Replace the hose and tube if damaged.
br9tbea
Valve Tappets and Push Rods - Group 04
614 Series Page 41
Valve Tappets and Push Rods - Group 04

Section Contents
Page
Push Rods - Cleaning and Inspection for Reuse ..................................... 4-4

Cleaning.. .............................................................. 4-4
Inspection ............................................................... 4-4
Valve Tappet Cleaning and Inspection for Reuse .................................... 4-3

Cleaning ................................................................ 4-3
Inspection ............................................................... 4-3
Valve Tappets and Push Rods - Exploded View ..................................... 4-2
Valve Tappets and Push Rods - General Information .................................. 4-3

Valve Tappets and Push Rods - Exploded View Valve Tappets and Push Rods - Group 04
Page 4-2 614 Series
Valve Tappets and Push Rods - Exploded View
Ref. No. Part Name QtY-

1 Tappet, Valve 12
2 Rod, Push 12
Valve Tappets and Push Rods - Group 04 Valve Tappets and Push Rods - General Information
614 Series Page 4-3
Valve Tappets and Push Rods - General

Information
The camshaft has lobes to operate the intake and exhaust
valves and a special lobe to drive the fuel transfer pump. The
valve lobes contact the valve tappets which lift the push rods
subsequently opening the valves.
The tappets are mushroom shaped and are positioned so the
centerline of the tappet is offset to the centerline of the
camshaft lobe. The offset position causes the tappet to rotate
as it lifts the push rod.
The ball end of the push rod fiis into the ball socket in the
tappet. The other end of the push rod has a ball socket in
which the ball end of the rocker lever adjusting screw
operates.
Valve Tappet Cleaning and Inspection for

Reuse (4-01)
Cleaning
NOTE: Do not mix the tappets.
Clean the tappets with solvent and dry with compressed air.
Caution: Any time a new camshaft is installed, new
q
\
tappets must also be installed to prevent damage to the

mating surface. A
Inspection
0+B
Inspect the socket, stem and face for excessive wear, cracks,
concavity and other damage.
Reuse Guidelines:
(A) - Normal wear

(B) and (C) - Abnormal wear - Do not reuse
Valve Tappet Face Concavity (Maximum)

mm in.
0.025 MAX 0.001 bpSfasa
Push Rods - Cleaning and Inspection for Reuse (4-02) Valve Tappets and Push Rods - Group 04
Page 4-4 614 Series
Measure the valve tappet stem.
Valve Tappet Stem Diameter

mm in.
15.925 MIN 0.627
15.980 MAX 0.629
0
Pit marks on the tappet face are acceptable.
a3 The following criteria definds the size of the pits allowed:
1. A single pit cannot be greater than 2 mm [0.078 inch].
2. Interconnection of pits is not allowed.
3. Total pits when added together should not exceed 6 mm
IO.236 inch] diameter or a total of 4 percent of the tappet
face.
4. No pitting is allowable on the edges of the wear face of
the tappet.
Push Rods - Cleaning and Inspection for

Reuse (4-02)
Cleaning
q
Use solvent or hot soapy water to clean the push rods. Dry
\ with compressed air. ’ *
Inspection
Visually inspect the push rod ball and socket for signs of
scoring, cracks, or other damage.
preoosc
Valve Tappets and Push Rods - Group 04 Push Rods - Cleaning and Inspection for Reuse (4-02)
614 Series Page 4-5
0et3
Check the push rods for straightness.
Push Rod Straightness

mm in.
0.50 MAX 0.020
pr900sb
Fuel Systems - Group 05
614 Series Page 5-l
Fuel Systems - Group 05

Section Contents
Page
Fuel Injection Pump Gaskets and Seals - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fuel System - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Derivative Fuel Injection Pump - Data Tag Information ................................ 5-3
Fuel Injection Pump ....................................................... 5-2
Fuel Injection Pump - Data Tag Information ....................................... 5-2
Fuel Injection Pump - Data Tag Location ......................................... 5-2
Fuel Shutoff Solenoid - Wiring Requirements ...................................... 5-3
Governor - Data Tag Information .............................................. 5-3
Fuel Transfer Pump - Exploded View ............................................ 5-4
Fuel Transfer Pump - Rebuild ................................................. 5-5

Cleaning.. ............................................................. 5-5
Assembly .............................................................. 5-5
RQVK Governor Fuel Shutoff Solenoid - Adjustment ................................. 5-9
RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment ....................... 5-6
Fuel Shutoff Solenoid - Adjustment ............................................. 5-8
Fuel Shutoff Solenoid - Orientation ............................................. 5-6
Shutdown Lever or Spring - Replacement ........................................ 5-10

Fuel System - General Information Fuel Systems - Group 05
Page 5-2 614 Series
Fuel System - General Information
Fuel Injection Pump
The Robert Bosch PESGA fuel injection pump is used on 614, 614T and 614TA series engine models. The Model PESGMW
pump is used on the higher rated 614TA engines.
The fuel injection pump is calibrated for a specified performance for the different engine applications and models. The
performance of the engine is defined by the the enigne part number and the fuel injection pump code.
During any fuel system repair, cleanliness is of utmost importance. Thoroughly clean all affected parts with solvent and
then blow dry with compressed air.
The fuel injection pump calibration must be within published specifications. The calibration is certified by several emissions
agencies. Tampering with the injection pump is a violation of law. Tampering with the fuel injection pump will void the
engine warranty and can lower the performance of the engine.
This manual does not cover fuel injection pump rebuild or calibration. Rebuild and calibration must be performed in a
facility certified in the rebuild and calibration of the fuel injection pumps. However, there are external repairs that can be
performed on the pumps without affecting the calibration. These repairs are included in this section of the manual.
Fuel Injection Pump - Data Tag Location

Fuel injection pumps have two and sometimes three data tags
(derivative pumps). These tags contain the information needed
to properly calibrate the pump (Bosch pump shown).
(A) Fuel Injection Pump Data Tag
(B) Governor Data Tag
G) Derivative Pump Data Tag
Fuel Injection Pump - Data Tag Information

1. Fuel Injection Pump Serial Number
2. Bosch Ten Digit Number
fP901 gl
Fuel Systems - Group 05 Fuel System - General Information
614 Series Page 6-3
Governor - Data Tag Information

2. Vendor Fuel injection Pump Part Number
Derivative Fuel Injection Pump - Data Tag

Information
This tag is installed on the fuel injection pump when a base
fuel injection pump is converted to a derivative fuel injection
pump.
Fuel Shutoff Solenoid - Wiring Requirements DUAL COIL SOLENOID

EXISTING STARTING
USED WlTH
SYSTEM
The solenoid must be wired properly. Refer to the chart

below to find the correct gauge size and length of
continuous wire for the white (pull-in) wire, which connects
the solenoid wiring. The black (ground) wire must be the
same gauge as the white (pull-in) wire regardless of its
length.
Length of Wires
O-4.5 ft O-7.0 ft O-11 ft
gauge 14 12 10
14 gauge wire is required for the red (hold-in) wire, which

connects to the “RUN” terminal on the ignition switch.
Wire Gauge Size*

mm in
1.5 14 0.060
1.9 12 0.076
2.4 10 0.096
* Diameter of conductor only. Does not include
insulation.
Fuel Transfer Pump - Exploded View Fuel Systems - Group 05
Page 6-4 614 Series
Fuel Transfer Pump - Exploded View
Ref. No. Description Quantity

1 Check Valve 2
2 Check Valve Gasket 2
3 O-Ring Seal 1
4 O-Ring Seal 3
Fuel Systems - Group 05 Fuel Transfer Pump - Rebuild (6-01)
614 Series Page 6-5
Fuel Transfer Pump - Rebuild (501)

20 mm, 26 mm Wrench
Caution: The hand-prime fitting and inlet fitting are spring
loaded. Sudden removal of these two fittings can cause
personal injury.
Secure the pump in a vise, taking care not to damage the
A
pump housing.
Remove the rubber boot from the hand-prime fiiing.
Remove the three fittings as illustrated.

(A) Outlet Fiiing
(B) Inlet Fitting
(C) Hand Primer Fitting
Remove all internal components of the pump.
NOTE: Make sure the check valve gaskets are removed from
the inlet fitting.
Cleaning
Thoroughly flush the
remove any debris.
pump with a cleaning solution to
q
\
Assembly
20 mm, 26 mm Wrench
Assemble the pump with the new components supplied in
the rebuild kit.
1. Check valves
2. Check valve gaskets
3. O-ring seal
4. Outlet fitting/check valve
5. O-ring seal (25 mm)
6. *O-ring seal (25 mm or 30 mm)
*O-ring required is determined by the size of the inlet fitting.
Discard unused o-ring.
RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (5-02) Fuel Systems - Group 05
Page 56 614 Series
NOTE: Extreme caution must be used to make sure the check

valves are installed to open in the direction of the fuel flow.
Improper installation of the check valves will result in low
power.
Place the pump in a vise and tighten the fiiings.

Torque Value:
(A) Outlet Fitting 30 Nom 122 ft-lb]
(B) Inlet Fiiing 30 Nom [22 ft-lb]
(C) Hand Primer Fitting 30 Nom [22 ft-lb]
I.-Y\ fs9OOwb
RSV Governor Fuel Shutoff Solenoid -

Orientation and Adjustment (5-02)
Fuel Shutoff Solenoid - Orientation
All 614 series engines that are equipped with a fuel shutoff
valve solenoid use either a Synchro-Start or a Trombetta
solenoid.
NOTE: To prevent moisture induced failure, all Trombetta
solenoids must be oriented in the 6:00 o’clock position
according to the following instructions:
Make sure all parts and mounting areas are free of dirt,
damage and other discrepant conditions. The plunger should
be free of rust.
Fuel Systems - Group 05 RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (6-02)
614 Series Page 5-7
Insert the solenoid through the bracket with the solenoid @Q

shaft toward the fuel pump. Make sure the rubber bellows
vent hole is in the 6:00 o’clock position. @
fV900vm
Apply hand pressure to relieve the solenoid spring pressure

and align the capscrew holes. This must be done to align the
plunger on the shut down lever, which is not shown in this
illustration.
fv9OOwb
Insert the capscrews through the solenoid and hand start

into the bracket.
fv9OOha

Connect the wiring harness.
RSV Governor Fuel Shutoff Solenoid - Orientation and Adiustment 6-021
. I
Fuel Svstems - Group 05
-.--
Page 5-8 814 Skies
Fuel Shutoff Solenoid - Adjustment

Synchro-Start
This procedure is for adjusting and maintaining Synchro-Start
fuel shutoff solenoids used to shut down Robert Bosch A/RSV
and MW/RSV fuel injection pumps.
NOTE: The adjustment for the Trombetta is similiar, refer to the

procedure on the following page. Refer to Service Bulletin
381034801 for additional fuel pump identification information.
8 mm
Adjust the solenoid mounting bracket so that the solenoid
plunger “targets” the center of the shutoff lever as shown in
the illustration.
Activate the solenoid and check the plunger travel. The

maximum stroke length when retracted must be so that there
is a 1 to 3 mm IO.040 to 0.118 inch] gap between the acorn
nut and the shutoff lever (full run position). The plunger length
can be adjusted by hand tightening or loosening the acorn nut.
Deactivate the solenoid and check the plunger travel. The

plunger must be extended so that the shutoff lever hits the shut
down stop screw. If necessary, adjust the acorn nut so the
shutoff lever will hit the stop screw.
Fuel Systems - Grout 05 RQVK Governor Fuel Shutoff Solenoid - Adjustment (B-03)
614 Siries Page 6-9
Measure distance A (solenoid mounting bracket to shutoff

lever) when the solenoid is deactivated. Activate the solenoid
and ‘measure distance B (mounting bracket to lever) when -
the solenoid is activated. The difference (A-B or plunger
stroke length) must be 25.4 mm [l inch] or less.
NOTE: Make sure that the engine shuts down completely
when the solenoid is deactivated, and starts immediately
when the solenoid is activated.
I-B-4 f”CX-l”“h
Trombetta
Trombetta solenoid adjustment is similar to the Synchro-Start
solenoid, but without an acorn nut adjustment. Plunger stroke
length must be 33.3 mm [1.3 inches] or less.
When the plunger is fully retracted, the gap must measure

between 1 mm to 3 mm [0.040 to 0.118 inch].
RQVK Governor Fuel Shutoff Solenoid -

Adjustment (503)
Activate the igniton switch and check the fuel shutoff
solenoid plunger travel.
A = 88.9 mm [2.&l in]
NOTE: Dimension A is measured from the bottom of the
mounting bracket to the top of the pivot pin.
/I
\ l-f
Shutdown Lever or Spring - Replacement (5-04) Fuel Systems - Group 05
Shutdown Lever or Spring - Replacement

(504)
Eil 10 mm
Remove the shutdown lever retaining screw.
@l
fv90om;
Remove the shutdown lever (A), spring housing (B) and return
spring (C).
U-J ’ fv9lvma
Install the return spring as illustrated.
Install the spring housing over the return spring and align the
outside tip of the return spring with the outside hole in the
spring housing as illustrated.
Fuel Systems - Group 05 Fuel Injection Pump Gaskets and Seals - Replacement (6-05)
Metal Awl or Pick

Load the return spring by rotating the return spring and
spring housing counterclockwise approximately l/4 turn.
10 mm
Hold the return spring in the loaded position and install the
shutdown lever.
10 mm
Install the shutdown lever retaining screw making sure the
return spring is installed into the hole in the shutdown lever.
fv900mz
Fuel Injection Pump Gaskets and Seals -

Replacement (5-05)
Bosch Fuel Injection Pumps
Item Type of Seal Torque Value

(A) Sealing Washer 24 Nom [18 k-lb]
(S) Gasket
(C) Gasket
0 Sealing Washer Only 15 Nom [ll k-lb]
(E) O-ring
03 O-ring
Injectors and Fuel Lines - Group 06
614 Series Page 6-l
Injectors and Fuel Lines - Group 06

Section Contents
Page
Fuel Drain Manifold - Inspection ................................................ 6-16
Fuel Lines, High Pressure - Cleaning and Inspection for Reuse .......................... 6-14
Fuel Lines - Cleaning and Inspection ............................................. 6-15
General Information ........................................................ 6-14
Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse .......................... 6-16
Injector - Chatter Testing ..................................................... 6-14
Injector - Spray Testing ...................................................... 6-13
Injectors and Fuel Lines - Exploded View .......................................... 6-3
Injectors and Fuel Lines - General Information ...................................... 6-7
Injectors and Fuel Lines - Service Tools .......................................... 6-2
Injectors - Cleaning and Inspection for Reuse ...................................... 6-8

General Information ........................................................ 6-6
Injector - Assembly ........................................................ 6-12
Injector - Cleaning and Inspection .............................................. 6-10
Injector - Disassembly ...................................................... 6-8
injectors and Fuel Lines - Service Tools Injectors and Fuel Lines - Group 06
Page 6-2 614 Series
Injectors and Fuel Lines - Service Tools
Tool No. Tool Descrbtion Tool Illustration

Injector Nozzle Tester
Used to test opening pressure, leakage, chatter and spray

3376946 pattern.
Nozzle Cleaning Kit
Used to clean injector nozzles.

3376947
Injectors and Fuel Lines - Group 06 Injectors and Fuel tines - Exploded View
Page 63
614 Series
Injectors and Fuel Lines - Exploded View

Injectors and Fuel Lines - Exploded View injectors and Fuel Lines - Group 06
Page 6-4 614 Series
Ref. No. Part Name
1 Screw, Hex Flange Head Cap 1
3 Seal, Banjo Connector 7
4 Screw, Banjo Connector 7
6 Manifold, Fuel 1
7 Washer, Sealing 6
8 Washer, Plain 9
9 Brace, Tube 4
10 Screw, Hexagon Head Cap 9
11 Isolator, Vibration 8
12 Brace, Tube 3
13 Brace, Tube 3
14 Tube, Injector Fuel Supply 1
17 Brace, Tube 1
18 Brace, Tube 1
19 Isolator, Vibration 2
20 Brace, Tube 1
24 Tube, Fuel Supply 1

Injectors and Fuel Lines - Group 06 Injectors and Fuel Lines - Exploded View
614 Series Page 6-5

1 Screw, Hexagon Head Cap 2
3 Gasket, Cover Plate 1
4 Pump, Fuel Transfer 1
5 Washer, Sealing 2
6 Tube, Fuel Supply 1

Injectors and Fuel Lines - Exploded View Injectors and Fuel Lines - Group 06
Page 6-6 614 Series
1 Seal, Banjo Connector 1
2 Seal, Injector 1
3 Seal, Injector 1
4 Injector 1
6 Clamp, Injector 6
Injectors and Fuel Lines - Group 06 Injectors and Fuel Lines - General Information
614 Series Page 6-7
Injectors and Fuel Lines - General Information

All614 Series engines use 17mm closed-nozzle, hole-type injectors.
The injector needle valve and the nozzle tip are machined to a very precise tolerance. Never replace only the needle
valve. Never mix the needle valves and nozzle tips, they are matched sets.
This group provides instructions for disassembly, cleaning, assembly and test of the injectors. This group also provides
data for the injector, high pressure fuel lines, and fuel transfer pump.
Injectors - Cleaning and Inspection for Reuse (6-01) Injectors and Fuel Lines - Group 06
Page 6-8 614 Series
Injectors - Cleaning and Inspection for

Reuse (6-01)
General Information
All engines use 17 mm closed nozzles, hole-type injectors.
However, the injectors can have different part numbers for
different engine ratings. The last four digits of the Vendor part
number are used to identify the injectors.
Use only the specified injector for the engine.
Injector - Disassembly
\
q Clean the carbon residue from the injector nozzle. Use a brass
wire brush and a piece of hardwood dipped in test oil.
Remove the injector seal and discard.
“3”
69 l
0
t
fi9ww.w
15 mm
Clamp an injector holddown clamp in a soft jawed vise to hold
the injector and remove the injector nozzle retaining nut.
flsnumt
Injectors and Fuel Lines - Group 06 Injectors - Cleaning and Inspection for Reuse (&Ol)
614 Series Page 69
Remove the nozzle needle valve and intermediate plate.

NOTE: To avoid damage, place the injector nozzle and
needle valve in a suitable bath of clean test oil.
NOTE: Hold the needle valve by the stem only. Secretions

from the skin will corrode the finely lapped surfaces.
NOTE: The needle valve and nozzle tip are precisely

matched for fit. The parts must not be intermixed.
fi900a
Remove the nozzle holder from the vise; then remove the
pressure spindle, pressure spring and shims. CB
0
I I fi900f.
Injectors - Cleaning and Inspection for Reuse (6-01) injectors and Fuel Lines - Group 06
Page 610 614 Series
Remove and discard the injector sealing sleeve.
fi9slm.3
J
Injector - Cleaning and Inspection
\
q
Rinse the nozzle bodies and needle valves in solvent to
thoroughly flush and completely remove all varnish and carbon
deposits.
Nozzle Cleaning Kit, Part No. 3376947

Eil Dip the nozzle seat in clean test oil and use the scraper to
\
q
clean. Polish the needle seat with the piece of hardwood
dipped in test oil.
Caution: Never use emery paper or any other metal scraper
to clean the nozzle. The parts can be damaged.
Nozzle Cleaning Kit, Part No. 3376947

Clean the interior ring groove of the nozzle with the scraper as
shown. Rinse in solvent to remove all dirt and carbon residue
and dip in clean test oil.
Injectors and Fuel Lines - Group 06 Injectors - Cleaning and Inspection for Reuse (6-01)
Clean the spray holes as shown with the appropriate size

cleaning needle.
Remove burned-on combustion deposits on all nozzles with a
commercially available cleaner. Rinse all parts in clean test
oil.
Clean the needle valve tip with a brass brush. Inspect for
rough surfaces or erosion. The pressure shoulder will
normally have a rough machined appearance.
NOTE: Deteriorated needle valves must be replaced as a
matched unit with their compatible nozzle body.
Dip the needle valve in clean test oil and insert the needle
valve all the way into the nozzle body.
-
Pull the needle valve one-third of the way out of the nozzle
body. Wiih the needle valve in the vertical position, the
needle valve must slide all the way back into the nozzle
body under its own weight.
w
4B
If the nozzle fails the slide test, clean and test the nozzle
again.
NOTE: Any needle valve and nozzle body assembly which

does not pass this test must be replaced.
Injectors - Cleaning and Inspection for Reuse (601) Injectors and Fuel Lines - Group 06
Injector - Assembly
NOTE: Make sure all mating surfaces and pressure faces are
thoroughly cleaned and lubricated with test oil before assembly.
New nozzles must be cleaned and lubricated before assembly.
Install the shims and pressure spring.

NOTE: Install the same thickness of shims that were
removed in disassembly. Use the pressure spring to make
sure the shims are installed flat.
Install the spindle.
Install the intermediate plate.

Injectors and Fuel Lines - Group 06 Injector - Spray Testing (6-02)
Install the needle valve and nozzle assembly.
15 mm
Install the nozzle retaining nut.
Torque Value: 30 Nom [22 f&lb]
Injector - Spray Testing (6-02)

Part No. 3376946, Injector Nozzle Tester
Warning: Keep your body clear of test spray. Test fluid
can be injected into the bloodstream causing blood
poisoning and possible death. A
NOTE: All nozzles must be tested for opening pressure,
chatter and spray pattern.
fi900d
Check the injector opening pressure.

(A) Open valve
(B) Operate the lever at one stroke per second
(C) ;EI;sthe pressure indicated when the injector spray
Injector - Chatter Testing (603) Injectors and Fuel Lines - Group 06
If the opening pressure does not meet specifications:

1. Add shims to increase pressure.
2. Remove shims to decrease pressure.
I fi9smvz
Leakage Test:
1. Open valve (A).
2. Operate the lever (B) to maintain a pressure of 20 bar
[290 psi] below opening pressure (C).
3. No drops should fall from the tip (D) within 10 seconds.
Injector - Chatter Testing (6-03)

The chatter test indicates the ability of the needle valve to
move freely and correctly atomize the fuel. An audible sound
should be heard as the valve rapidly opens and closes. A well
optomized spray pattern should be seen.
Used nozzles should not be evaluated for chatter at lower
speeds. A used nozzle can generally be used if it passes the
leakage test.
Fuel Lines, High Pressure - Cleaning and

General Information
The high pressure fuel lines are designed and manufactured to
deliver fuel at injection pressure to the injectors. The high
pressure pulses cause the lines to expand and contract during
the injection cycle.
NOTE: The high pressure fuel lines must be clamped
securely and routed so they do not contact each other or
any other component.
Injectors and Fuel Lines - Group 06 Fuel Lines, High Pressure - Cleaning and Inspection for Reuse (6-04)
Caution: Do not weld or substitute

specified part number for the engine.
lines; use only the
The length, internal size and rigidity of the lines is criiical for
A
smooth engine operation. An attached metal tag is used to
identify each line with a part number.
Fuel Lines - Cleaning and Inspection

Wash the fuel lines in clean solvent and blow dry with
compressed air. Make sure all paint chips are removed.
@!3
0
ft9tbs
Visually inspect .the high pressure fuel lines for obvious

damage such as lines that have bent to facilitate injector 49
removal. High pressure pulses expand and contract the 0
injector lines which result in internal flaking at the bent areas.
Bent lines should be replaced.
Visually inspect for cracks at both ends of the fuel lines.
ft9tbs
Fuel Drain Manifold - Inspection (605) Injectors and Fuel Lines - Group 06
Page 816 614 Series
Inspect all fuel line fittings (l), support bracket capscrews (2)
vibration isolator capscrews (3) and isolators (4) for wear and
damage. Any damaged parts must be replaced.
Fuel Drain Manifold - Inspection (6-05)

Inspect the fuel drain manifold for cracks or damage.
ft9tbsc
Inspect the fuel drain manifold banjo connections.

NOTE: The banjo connection seals must be discarded when
removed. The seals must not be used again.
ft9tbsd
Fuel Lines, Low Pressure - Cleaning and

Wash the low pressure fuel lines in clean solvent. Blow dry with
compressed air.
Injectors and Fuel Lines - Group 06 Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse (6-06)
614 Series Page 617
0423
Visually inspect the fuel lines and banjo connections for
obvious damage such as cracks, bends or worn areas.
NOTE: The sealing washer must be discarded when
removed. The washer must not be used again.
Lubricating Oil System - Group 07
614 Series Page 7-l
Lubricating Oil System - Group 07

Section Contents
Page
Lubricating Oil Dipstick - Calibration ............................................ 7-13
Lubricating Oil Pan - Cleaning and Inspection for Reuse .............................. 7-5
Cleaning ............................................................... 76
Inspection .............................................................. 7-5
Lubricating Oil Pump - Cleaning and Inspection for Reuse ............................ 7-14
Cleaning ............................................................... 7-l 5
Disassembly ............................................................ 7-l 4
Inspection .............................................................. 7-15
Lubricating Oil System - Exploded View .......................................... 7-4
Lubricating Oil System - General Information ...................................... 73

Dipstick ............................................................... 7-3
Lubricating Oil Cooler and Filter Head ........................................... 7-3
Lubricating Oil Pump ...................................................... 7-3
Oil Filter Head.. ......................................................... 7-3
Oil Pan ...... . ........................................................ 7-3
Oil Pressure Regulator ..................................................... 7-3
Oil Temperature Thermostat .................................................. 7-3
Lubricating Oil System - Service Tools .......................................... 7-2
Lubricating Oil Temperature Thermostat - Cleaning and Inspection ....................... 7-12

Cleaning ............................................................... 7-12
Inspection ............................................................... 7-12
Oil Cooler Cover - Disassembly and Assembly ..................................... 7-l 0

Assembly .............................................................. 7-11
Cleaning ............................................................... 7-10
Disassembly ............................................................ 7-l 0
Oil Cooler Element - Cleaning and Inspection for Reuse .................. i ........... 7-6
Cleaning ............................................................... 7-6
Inspection .............................................................. 7-6
PressureTest ........................................................... 7-6
Oil Filter Bypass Valve - Replacement ........................................... 7-9
Oil Pressure Regulating Valve - Cleaning and Inspection .............................. 7-7

Assembly .............................................................. 7-6
Cleaning ............................................................... 78
Disassembly ............................................................ 7-7
Inspection .............................................................. 7-3
Lubricating Oil System - Service Tools Lubricating Oil System - Group 07
Page 7-2 614 Series
Lubricating Oil System - Service Tools
Used to remove and install the lubricating oil filters.
Measures spring force at a given spring height.
Used to open the full-flow oil filter for filter element inspection.
Used to pressure test the lubricating oil cooler element.

Lubricating Oil System - Group 07 Lubricating Oil System - General Information
614 Series Page 7-3
Lubricating Oil System - General Information

The lubricating oil system group consists of the oil pan, oil suction tube, oil dipstick and tube, oil filter head, oil cooler
element, oil temperature thermostat, oil pressure regulator and the lubricating oil pump.
Instructions for pressure testing the lubricating oil cooler element are included in this section. The oil cooler does not have
a replaceable element and cannot be rebuilt in the field.
Lubricating Oil Cooler and Filter Head
The oil cooler cover and filter head are combined into one casting. The oil pressure regulator, oil temperature thermostat
and filter bypass valve are also located in this housing.
Oil Pressure Regulator
A pressure regulator valve is used to provide pressure relief during cold starting and to regulate oil pressure after the oil
is warm.
Oil Filter Head
The oil filter head is an integral part of the oil cooler housing cover and includes a filter bypass valve. The filter bypass
valve is designed to maintain oil flow to the engine if the oil filter becomes plugged.
Oil Temperature Thermostat
An oil temperature thermostat is located in the top of the oil cooler housing. The thermostat modulates oil flow at
temperatures between 100” and 115°C [212” and 239”F] and full flow through the oil cooler at oil temperatures above
115°C [239”F]. The thermostat also incorporates a pressure relief feature which allows oil to bypass the cooler should
it ever become plugged.
Lubricating Oil Pump
It is not practica.to rebuild the gerotor type lubricating oil pump. It can be reused if it meets the inspection criteria.
Dipstick
A center-mounted dipstick location is used on either side of the cylinder block for all oil pans. Service replacement oil
dipsticks do not have the high and low oil level marks indicated on the dipstick. The dipstick must be calibrated after
the engine is installed in the chassis.
Oil Pan
There are two oil pan options available. One oil pan provides a center sump arrangement. The other oil pan can be used
to provide either a front or a rear sump with the use of the corresponding internal oil suction tube. Both oil pans have
the same capacity.
Lubricating Oil System - Exploded View Lubricating Oil System - Group 07
Page 7-4 614 Series
Lubricating Oil System - Exploded View
Ref. No. Description Qv Ref. No. DescriDtion Qtv

1 Gasket, Suction Tube 1 23 . Plug, Pipe 1
2 Tube, Lube Oil Suction 1 24 Seal, O-Ring 1
3 Screw, Socket Head Cap 2 25 Element, Lube Oil Filter 1
4 Spacer, Mounting 2 26 Screw, Hex Flange Head Cap 11
5 Brace, Suction Tube 1 27 Gasket, Oil Cooler Element 1
6 Screw, Hex Head Cap 2 28 Element, Oil Cooler 1
7 Screw, Hex Head Cap 1 29 Gasket, Lube Oil Cooler Cvr. 1
8 Washer, Plain 1 30 Plunger, Pressure Regulator 1
9 Nut, Hex Flange 1 31 Dowel, Ring 1
10 Gasket, Oil Pan 1 32 Gasket, Filter Head 1
11 Pan, Oil 1 33 Valve, Bypass 1
12 Screw, Hex Head Cap 32 34 Screw, Hex Flange Head Cap 4
13 Washer, Spring 32 35 Head, Lube Oil Filter 1
15 Washer, Sealing 1 36 Cover, Lube Oil Cooler 1
16 Plug, Threaded 1 37 Thermostat, Lube 1
17 Plug, Threaded 1 38 Plug, Threaded 1
18 Washer, Sealing 1 39 Plug, Expansion 1
19 Spring, Compression 1 40 Dipstick 1
20 Seal, O-Ring 1 41 Tube, Oil Gauge 1
21 Plug, Pipe 2 42 Pump, Lubricating Oil 1
22 Plug, Pipe 1 43 Screw, Hexagon Head Cap 4
Lubricating Oil System - Group 07 Lubricatina Oil Pan - Cleaning and Inspection for Reuse (7-01)
614 Seried Page 7-5
Lubricating Oil Pan - Cleaning and

Cleaning
q
Remove all gasket material from the oil pan gasket sealing
surface. B
- ^
A
Use steam to clean the oil pan and suction
compressed air.
tube. Dry with
q
\
0+B
Inspection
Visually inspect the oil pan for cracks or damage.
Visually inspect the oil drain plug threads for damage.
Do not use a damaged oil drain plug or oil pan.
op90osa
0a9
Visually inspect the oil suction tube and brace for cracks. Do
not reuse a cracked oil suction tube or brace.
op9tbsa
Oil Cooler Element - Cleaning and Inspection for Reuse (7-02) Lubricating Oil System - Group 07
Page 7-6 614 Series
Oil Cooler Element - Cleaning and

Cleaning
Plug the cooler element and soak it in a cleaning solution to
remove the coolant deposits.
Remove the plugs and soak the cooler element in solvent.

NOTE: The cooler element can be cleaned in a hot tank.
If the oil passages are contaminated by foreign material, the oil
cooler must be replaced.
‘:
Back flush the oil passages with clean solvent and use
compressed air to dry.
I.
%
Inspection
Inspect the soldered joints for corrosion or cracks.
Check the element for flatness.
Oil Cooler Element Distortion

mm in
0.8 MAX 0.031
I lc9etka
Pressure Test
Part No. 3823876 Lubricating Oil Cooler Pressure Test Kit
Install the oil cooler test fixture to the cooler element.
Connect a regulated air line and apply 483 kPa 170 psi] air
pressure to the element.
lc9toha
Lubricating Oil System - Group 07 Oil Pressure Regulating Valve - Cleaning and Inspection (7-03)
Page 7-7
614 Series
Install the oil cooler element in a tank of water.

Temperature: 82” [18O”F]
Check for leaks.
If leaks are found in the oil cooler element, the element must
be replaced.
0a9
Remove the oil cooler form the tank of water.

Remove the pressure test equipment.
Use compressed air to dry the oil cooler.
Cover all of the openings with tape to prevent dirt from
L
entering the element when it is not in use.
r
Oil Pressure Regulating Valve - Cleaning

and Inspection (7-03)
Disassembly
22 mm
Ezl
Remove the threaded plug and o-ring seal.
c%
0
Remove the spring and pressure regulator plunger. l

@
lc9pgma
Oil Pressure Regulating Valve - Cleaning and Inspection (7-03) Lubricating Oil System - Group 07
Page 7-a 614 Skies
Cleaning
Clean all parts in solvent and use compressed air to dry.
Inspection
Inspect the plunger bore for nicks or scratches.
NOTE: The plunger must move freely in the bore.
lc9pgka
Check the spring tension and free length. Replace the spring
if the measurements do not meet the specifications.
Lubricating Oil Pressure Regulator Spring Specifications

Valve Open
Height: 53.98 mm [2.125 inches]

Load: 190 N [42.8 Ibfl
Assembled
Height: 50.33 mm [2.375 inches]

Load: 153 N [34.4 Ibfl
icsspna
Assembly
22 mm
Install the pressure regulating plunger and spring.
Install a new o-ring seal and plug.
lc9vaha
Lubricating Oil System - Group 07 Oil Filter Bypass Valve - Replacement (7-04)
614 Series Page 7-9
Oil Filter Bypass Valve - Replacement

(7-04)
10 mm
Remove the oil filter head and discard the gasket.
lc9hdm.a
Remove the oil filter bypass valve form the cooler cover.
Drive the new oil filter bypass valve in until it is fully seated
against the step int the bore.
10 mm
lnstal the oil filter head and new gasket. Tighten the
capscrews.
Torque Value: 24 N*m [I8 ft-lb]
lc9hdma
Oil Cooler Cover - Disassembly and Assembly (7-05) Lubricating Oil System - Group 07
Oil Cooler Cover - Disassembly and

Assembly (7-05)
Disassembly
10 mm
Remove the oil filter head and discard the gasket.
lc9hdma 1
32 mm
Remove the oil temperature thermostat and discard the o-ring.
Refer to Procedure 7-06 for cleaning and inspection.
Remove the pipe plugs form locations (l), (2), (3) and (4).
lcspxmc
Cleaning
Remove the oil pressure regulator plug, spring and plunger.
Discard the o-ring seal.
Refer to Procedure 7-03 in this section.
Clean all parts with solvent. Dry with compressed air.
lc9bdec
Lubricating Oil System - Group 07 Oil Cooler Cover - Disassembly and Assembly (7-05)
Assembly
Install and tighten all pipe plugs.
Torque Value:
(1) 10 Nom [89 in-lb]
(2) 10 Nom [89 in-lb]
(3) 45 Nom (33 ft-lb]
(4) 36 Nom [27 in-lb]
32 mm
Lubricate the oil temperature thermostat o-ring with vegetable
oil. Install and tighten the thermostat.
10 mm
Install the oil filter head and a new gasket.
I lc9hdma
Install the oil pressure regulator plug, spring and plunger.

Refer to Procedure 7-03 in this section.
Lubricating Oil Temperature Thermostat - Cleaning and Inspection (7-06) Lubricating Oil System - Group 07
Lubricating Oil Temperature Thermostat -

Cleaning and Inspection (7-06)
Remove the oil temperature thermostat from the oil cooler
cover. Refer to Procedure 7-05.
lc900ma
Cleaning
Clean the thermostat with solvent. Dry with compressed air.
Inspection
Visually inspect for a broken or damaged spring or other
damage.
Caution: The flash point of new lubricating oil is

approximately 221” [43O”Pj. Do not allow oil temperature in
the container to exceed 150°C [3OO”Fj. Do not allow water
droplets to enter the container of hot oil. Water droplets will
cause a violent reaction which can cause personal injury.
Lubricating Oil System - Group 07 Lubricating Oil Dipstick - Calibration (7-07)
Suspend the thermostat and a 116°C [24O”F] thermometer in

a container of new lubricating oil. Do not allow the
thermostat or the thermometer to touch the side or bottom
of the container.
Heat the lubricating oil.
lc900sb
NOTE: Write down the temperature at which the thermostat

is fully extended. The thermostat must be fully extended to
at least 45.9 mm [1.80 inch] when the temperature reaches
116°C [24O”F].
Replace the thermostat if it does not operate as described.
1
45.9 mm
[1.80 in]
Lubricating -Oil Dipstick - Calibration

(7-07)
Install the dipstick in the dipstick tube housing.
Use clean 15W-40 engine oil to fill the oil pan to the
specified “low” oil level. Refer to Lubricating Oil System
Specifications for engine oil capacity.
Caution: The dipstick will break if the scribe mark is too

deep.
Remove the dipstick and scribe a mark across the dipstick
and mark the “low” oil level with an ‘I”.
NOTE: If a new blank dipstick is being used, cut the dipstick
off approximately 38 mm [1.5 inches] below the “low” oil
level mark.
Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08) Lubricating Oil System - Group 07
Install the dipstick into the dipstick tube housing.

Fill the oil pan to the specified “high” oil level. Refer to
Lubricating Oil System Specifications for engine oil capacity.
Caution: The dipstick will break if the scribe mark is too

deep.
Remove the dipstick and scribe a mark across the dipstick and
mark the “high” oil level with and “H”.
Lubricating Oil Pump - Cleaning and

Disassembly
Visually inspect the lubricating oil pump gears for chips, cracks,
or excessive wear.
NOTE: It is not practical to rebuild the pump. If any of the
internal parts are worn beyond the specifications, the pump
must be replaced.
Remove the back plate.
lpeplma
Lubricating Oil System - Group 07 Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)
Mark “top” on the gerotor planetary.
lp900gb
Remove the gerotor planetary.

Inspect for excessive wear of scoring.
Cleaning
Clean all parts in solvent and use compressed air to dry.
q
\
Inspection
Inspect the pump housing and gerotor drive for damage and
excessive wear. 0
@
Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08) Lubricating Oil System - Group 07
Install the gerotor planetary.

Be sure the gerotor planetary is installed in the original
position.
Measure the tip clearance.
Lubricating Oil Pump Gerotor Tip Clearance

mm in
0.025 MIN 0.001

0.1778 MAX 0.007
Measure the clearance of the gerotor drive/gerotor planetary to

port plate.
Oil Pump Gerotor Drive/Gerotor Planetary to Port Plate

Clearance
mm in
0.025 MIN 0.001

0.127 MAX 0.005
IpSOOnb
Measure the clearance of the gerotor planetary to the body

bore.
Oil Pump Gerotor Planetary to Body Bore

mm in
0.127 MIN 0.005

0.381 MAX 0.015
lpsoonc
Lubricating Oil System - Group 07 Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)
Measure the gear backlash.
Oil Pump Drive Gear Backlash (Used Pump)

mm in
0.08 MIN 0.003
0.45 MAX 0.018
lp900nd
Install the back plate.
lp3plha
Cooling System - Group 08
614 Series Page 8-l
Cooling System - Group 08

Section Contents
Page
Belt Tensioner Inspection .................................................... 8-10
Coolant Filter Shutoff Valve - Cleaning and Inspection for Reuse ........................ 8-10
Assembly .............................................................. 8-11
Cleaning ............................................................... 8-11
Disassembly ............................................................ 8-10
Cooling System Components - Exploded View ..................................... 8-3
Cooling System - General Information ........................................... 84

Belt Tensioner ........................................................... 84
Cooling Fans ........................................................... 84
Fan Hub .............................................................. 84
Pressure Caps ........................................................... 84
Thermostats ............................................................ 84
Water Pump ............................................................ 84
.
Cooling System - Service Tools ............................................... 8-2
Fan Hub - Cleaning and Inspection for Reuse ..................................... 8-7

Cleaning ............................................................... 8-7
Inspection .............................................................. 8%
Fan Hub- Rebuild ......................................................... 8%

Assembly .............................................................. 8-9
Disassembly ............................................................ 8-8
Thermostat Housing - Cleaning and Inspection for Reuse ............................. 8%

Cleaning ............................................................... 8%
Inspection .............................................................. 8%
Thermostat - Inspection ..................................................... 8%
Water Outlet Connection - Cleaning and Inspection for Reuse .......................... 8-7
Water Pump Assembly - Cleaning and Inspection for Reuse ........................... 8-5
Cleaning ............................................................... 8-5
Inspection .............................................................. 8%
Cooling System - Service Tools Cooling System - Group 08
Page 8-2 614 Series
Cooling System - Service Tools
Dial Indicator and Sleeve Assembly
Use with Magnetic Base, Part No. 3377399, to measure the fan
3375950 hub and clearance.
Magnetic Base Dial Indicator Holder
Used with Part No. 3376050, Dial Indicator and Sleeve

3377399 Assembly.
Cooling System - Group 08 Cooling System Components - Exploded View
614 Series Page 8-3
Cooling System Components - Exploded View
Ref. No. Description QtY Ref. No. Description QtY

1 Pump, Water 1 21 Elbow, Male Adapter 2
2 Body, Water Pump 1 22 Plug, Pipe 1
3 Bearing, Water Pump 1 23 Draincock 1
4 Seal, Water Pump 1 24 Tube, Vent 1
5 Impeller 1 25 Support, Fan 1
6 Pulley, Water Pump 1 26 Bearing, Shaft 1
7 O-ring 1 27 Hub, Fan 1
8 Screw, Hex Head Cap 3 28 Retainer, Fan Hub 1
9 Thermostat, Coolant 2 29 Screw, Hex Head Cap 1
10 Gasket, Thermostat Housing 1 30 Screw, Hex Head Cap 4
11 Housing, Thermostat 1 31 Pulley, Fan 1
12 Screw, Hex Head Cap 2 32 Plate, Clamping 1
13 Connection, Water Outlet 1 33 Screw, Cap 4
14 Gasket, Connection 1 34 Screw, Cap 4
15 Screw, Hex Head Cap 2 35 Bracket, Belt Tensioner 1
16 Seal, O-ring 1 36 Screw, Flat Head Cap 2
17 Shaft, Shutoff Valve 1 37 Tensioner, Belt 1
18 Screw, Hex Head Cap 1 38 Screw, Hex Head Cap 1
19 Adapter, Filter Head 1 39 Belt, V-ribbed 1
20 Filter, Coolant 1
Cooling System - General Information Cooling System - Group 08
Page 8-4 614 Series
Cooling System - General Information
Water Pump
The water pump is a belt driven, centriiugal type pump with the inlet and bypass line as an integral part of the cylinder
block.
The coolant pressure can be measured from the vent petcock. At normal operating temperature (thermostats open) and
at 2,000 RPM the minimum pressure should be: 124 kPa [18 psi] with a 103 kPa [15 psi] pressure cap or 59 kPa [lo
psi] with a 48 kPa [7 psi] pressure cap. It is not practical to replace the parts in the pump, the water pump is serviced
as an assembly.
Thermostats
The thermostat housing contains two identical thermostats.
A Caution: Never operate the engine without the thermostats. The path of least resistance for the coolant
without thermostats is through the bypass to the water pump inlet. This will cause the engine to overheat.
Pressure Caps
The cooling system is designed to use a pressure cap to prevent boiling of the coolant. Different caps are specified for
the two recommended systems. The 104” C [220” F] system requires a 103 kPa [15 psi] cap. The 99°C [210” F] system
requires a 48 kPa [7 psi] cap.
Fan Hub
The fan hub is available in various drive ratios and fan center locations.
Belt Tensioner
The fan belt is tensioned by the spring loaded idler assembly and does not require adjustment.
To prevent accidents, always release the spring tension before replacing the fan belt.
Cooling Fans
See the appropriate Machine Chassis Shop Manual for cooling fan information.
Cooling System - Group 08 Water Pump Assembly - Cleaning and Inspection for Reuse (8-01)
814 Series Page 8-5
Water Pump Assembly - Cleaning and

Cleaning
The water pump seal design requires a coolant film for
lubrication and cooling. Therefore, it is normal to observe a
0a3
minor chemical buildup or streaking at the weep hole. Before
cleaning the water pump, inspect the weep hole for large
amounts of chemical buildup. Replace the pump if large
amounts of chemical buildup is observed.

A
Use solvent or steam to clean the water pump exterior.
Dry
q
\
Inspection
04B
Visually inspect the water pump body for cracks or damage.
Visually inspect the impeller for cracks, erosion, or damage.
Visually inspect the pulley for damage or wear.
;hsa
0a3
Rotate the water pump shaft by hand to inspect the bearings
and the impeller for freedom of rotation.
NOTE: If damaged parts are found or the shaft does not
rotate freely in the water pump body, the water pump must
be replaced.
NOTE: Parts replacement is not practical: the water pump is
serviced as an assembly.
Thermostat Housing - Cleaning and Inspection for Reuse (8-02) Cooling System - Group 08
Page 8-8 614 Series
Thermostat Housing Cleaning and

Inspection Reuse (8-02)
Cleaning
\
q
Use a
of
to remove
housing.
gasket material from the
th9hsea
A Warning:
clothing and
using steam cleaner, wear protective
or face shield. Hot steam will
\
q Use solvent or steam
a3
0 or if
th9hssa
4B
0
Cooling System - Group 08 Water Outlet Connection - Cleaning and Inspection for Reuse (8-04)
614 Series Page 8-j
Suspend the thermostats and a 100°C [212”F] thermometer

in a container of well mixed water.
NOTE: Do not allow the thermostats or thermometer to
touch the container.
Heat the water slowly so the wax element in the thermostats
has sufficient time to react to the rising water temperature.
Check the thermostats as follows:
NOTE: The nominal operating temperature is stamped on the

thermostat.
l Thermostat must begin to open within 1“C [2” F] of
82°C [13O”F].
l Thermostat must be fully open within 1°C [2”F] of
95” C [203” F] .
NOTE: The fully open clearance between the thermostat flow
valve and flange must be 41.5 mm [1.63 inches] minimum.
ec9aona
Water Outlet Connection - Cleaning and

Straight Edge
Use a gasket scraper to remove the gasket material from the
flange.
Clean with solvent. Dry with compressed air.
Check the water outlet connection for flatness.
Visually inspect for corrosion, cracks or damage.
Fan Hub - Cleaning and Inspection for

Reuse (8-05)
Cleaning
Use solvent or steam to clean the fan hub exterior. Dry with
compressed air.
Fan Hub - Rebuild (8-06) Cooling System - Group 08
Page 8-8 614 Series
Inspection
Visually inspect the fan hub for indication of oil seal leakage.
Visually inspect the fan hub for cracks or damage.
Turn the fan hub shaft by hand to check for freedom of

rotation. The fan hub must spin freely without any wobble or
Gt3 i
excessive end clearance.
fa900sb
Measure the fan hub shaft end clearance.
Fan Hub Shaft End Clearance

mm in
U 0.15 MAX 0.006

0
If damaged parts are found, the shaft does not rotate freely or
the shaft end clearance is not within the specifications, the fan
hub must be rebuilt or replaced.
0
0 ?
@--: (’ fasoona
Fan Hub - Rebuild (8-06)

Disassembly
16 mm
Secure the fan hub and remove the center bolt and retainer.
Cooling System - Group 08 Fan Hub - Rebuild (8-08)
814 Series Page 8-9
Install a bearing splitter as illustrated.

NOTE: Do not overtighten the bearing splitter as it may RI
damage the shaft when the bearing is pressed out.
3/4 inch Drift

Support the fan hub housing/splitter and press out the shaft.
0
C%
faeshma
2 inch Pipe
Support the fan hub housing and press out the bearing.
fa9bema
Assembly
Caution: Do not press on the inside diameter of the
bearing. The bearing could be damaged.
Press the new bearing into the fan hub housing even with
the front of the housing.
Fan Hub Bearing Installation Force

N Ibf
9000 MIN 2023
Replace the fan hub housing if the installation force is less fa9beha
than specified.
Belt Tensioner inspection (8-07) Cooling System - Group 08
l-1/2 inch Pipe (inside diameter)

Caution: Make sure the inner race is adequately supported
to avoid damage to the bearing. Do not press on the fan
hub.
Support the bottom of the inner race and press the shaft in
until it is seated.
Check the assembled height. If the assembled height is
incorrect, disassemble and assemble with a new bearing.
Fan Hub Assembled Height

mm in.
fa9shha
124.85 MIN 4.915

125.65 MAX 4.946
16 mm
Secure the fan hub assembly and install the center bolt arid
retainer.
Belt Tensioner Inspection (8-07)

Rotate the pulley to check for freedom of rotation and that
there are no rough spots on the bearing.
Check for a broken spring or damaged locating tang.
NOTE: It is not practical to rebuild the belt tensioner, if
damaged, the complete assembly must be replaced.
.
fn900sa
Coolant Filter Shutoff Valve - Cleaning

and Inspection for Reuse (8-08)
Disassembly
Remove the retaining capscrew (1) from the thermostat housing
(2) and remove the shutoff valve (3).
Remove and discard the o-ring (4).
Cooling System - Group 08 Coolant Filter Shutoff Valve - Cleaning and Inspection for Reuse (8-08)
614 Series
Page 8-l
Cleaning
Use solvent to clean the parts. Dry with compressed air.
q \
04B
Visually inspect the water passages in the shutoff valve shaft.
Visually inspect the shaft for corrosion or pitting. Use 240 grit
aluminum oxide paper to remove the corrosion.
If the parts are cracked or damaged, the filter head assembly
must be replaced.
th9vas.a
Assembly
Install a new o-ring in the groove of the shaft.
I th9orha
q
Use clean 15W-40 engine oil to lubricate the shaft and o-ring. k
1
I \ wf2vawa
Belt Tensioner Inspection (8-07) Cooling System - Group 08
Install the shutoff valve shaft (3) in the thermostat housing (2).
Install the retaining capscrew (1) in the thermostat housing.
Tighten the capscrew.
Torque Value: 7 Nom [fX in-lb]
thSboha
Drive Units - Group 09
614 Series Page 9-l
Drive Units - Group 09

Section Contents
Page
Accessory Drive Adapter - Cleaning and Inspection for Reuse .......................... 46

Cleaning ............................................................... 4-5
Inspection .............................................................. 4-5
Accessory Drive Adapter - Exploded View ........................................ 4-3
Accessory Drive Adapter - Rebuild ............................................. 4-5

Assembly .............................................................. 4-6
Disassembly ............................................................ 4-6
Accessory Drive - General Information ........................................... 4-4

Accessory Drive Adapter .................................................... 4-4
Drive Units - Service Tools ................................................... 4-2

Drive Units - Service Tools Drive Units - Group 09
Page 9-2 614 Series
Drive Units - Service Tools
. __. Nn.
Tnnl .-_. Tool Descrintion Tool Illustration
Standard Puller
Used to remove drive gears.

ST-647
Drive Units - Group 09 Accessory Drive Adapter - Exploded View
614 Series Page 9-3
Accessory Drive Adapter - Exploded View
Ref. No. Part Name QtY-

1 Adapter, Accessory Drive 1
2 Bearing 1
3 Shaft, Accessory Drive 1
4 Gear, Accessory Drive 1
5 Gasket, PTO Drive Cover 1
6 Screw, Hex Head Cap 2
7 Gasket, PTO Drive Cover 1
8 Plate, PTO Drive Cover 1

Accessory Drive - General Information Drive Units - Group 09
Page 9-4 614 Series
Accessory Drive - General Information

Accessory Drive Adapter
The accessory drive is gear driven from the camshaft gear in the front gear train. The accessory drive is capable of driving
up to a maximum of 105 ft-lb of torque. The accessory drive is equipped with either SAE A or B flange adapters.
A cover plate is used for engines not equipped with an air compressor or hydraulic pump.
Drive Units - Group 09 Accessory Drive Adapter - Cleaning and Inspection for Reuse (9-01)
614 Series Page 9-5
Accessory Drive Adapter - Cleaning and

Cleaning
Clean the accessory drive adapter with clean solvent and
blow dry with compressed air.
Inspection
Visually inspect for obvious damage such as cracks, broken
0a?
teeth and damaged threads.
0@B
Rotate the gear and inspect for rough spots in the bearing
and excessive wear.
u I ad900sb
Accessory Drive Adapter - Rebuild (9-02)

Disassembly
ST-647 T Bar Puller
Remove the drive gear. RI
c%
4
Accessory Drive Adapter - Rebuild (9-02) Drive Units - Group 09
Page 9-6 614 Series
NOTE: The shaft/bearing assembly will only press out in one

direction.
P Press the shaft and bearing assembly out as illustrated.
Press the shaft out of the bearing and discard the bearing.
The bearing must not be used again.
! ad9OOfc
Assembly
1 l/2 inch ID Pipe Coupling
Support the inner race of the new bearing and press the shaft
into the bearing until the shaft seats on the inner race.
ad900aa
2 inch ID Pipe
Caution: To prevent damage to the bearing, do not press
on the inner race, only press on the outer race of the
bearing assembly.
Support the housing and press the bearing and shaft assembly
in until it is seated.
Drive Units - Group 09 Accessory Drive Adapter - Cleaning and Inspection for Reuse (9-01)
614 Series Page 9-7
Position the gear with the lip facing down.
1 l/4 inch Pipe Coupling

Support the bottom of the shaft with a 1 l/4 inch pipe
coupling and press the gear on until it seats against the
inner-bearing race.
ad900ad.
Air Intake System - Group 10
614 Series Page 10-l
Air Intake System - Group IO

Section Contents
Page
Aftercooler Assembly - Cleaning and Inspection for Reuse ............................. IO-7

Inspection............................................................... IO-8
Aftercooler Assembly - Rebuild ................................................. IO-8
Air Crossover Tube - Cleaning and Inspection for Reuse ............................... IO-9
Cleaning................................................................lO- 9
Inspection............................................................... IO-9
Air Intake System - ExplodedView ............................................ ..I0 3
Air Intake System - General Information ........................................... IO-4
Air Intake System - Service Tools ............................................... 10-2
Air Transfer Pipe - Cleaning and Inspection for Reuse ................................ 10-9
Cleaning................................................................lO- 9
Inspection............................................................... IO-9
Intake Manifold Cover - Cleaning and Inspection for Reuse ............................. IO-7
Inspection ............................................................... 1O-7
Turbocharger - Cleaning and Inspection for Reuse ................................... 10-5

Inspection ............................................................... 1O-5
Air Intake System - Service Tools Air Intake System - Group 10
Air Intake System - Service Tools
S”“, I.“. I “V, Yeaw ,puw, 1001 ~iiusmwuii
Dial Depth Gauge
Measure the turbocharger axial motion.

ST-537
Pressure Test Kit
Used to test the turbocharger wastegate actuator.

3823799
Air intake System - Group 10 Air Intake System - Exploded View
Air Intake System - Exploded View

1 Turbocharger 1 26 Lock Plate 12
2 Gasket, Turbocharger 1 27 Manifold, Exhaust 1
3 Stud 4 28 Gasket, Exhaust Manifold 6
4 Nut, Regular Hex 4 29 Screw, Hex Head Cap 12
5 Screw, Hex Head 5 30 Gasket, Aftercooler 1
6 Connector, Adapter 1 31 Aftercooler 1
7 Screw, Flange Head 3 32 Screw, Hex Head Cap 18
8 Washer, Plain 3 33 Hose, Plain 1
9 Clamp, V Band 1 34 Clamp, Hose 2
10 Nut, Hex 1 35 Hose, Flexible 1
11 Brace, Actuator 1 36 Conn., Female 1
12 Nut, Lock 1 37 Gasket, Turbo. Oil Drain 1
13 Actuator, Turbocharger 1 38 Tube, Turbo. Oil Drain 1
14 Bracket, Actuator 1 39 Screw, Hex Head Cap 2
15 Screw, Hex Head 3 40 Hose, Plain 1
16 Washer, Plain 3 41 Clamp, Hose 2
17 Nut, Hex Jam 1 42 Tube, Turbo. Oil Drain 1
18 Ring, Retaining 1 43 Elbow, Hose Adapter 2
19 End, Adjusting Link 1 44 Seal, O-Ring 2
20 Connection, Air Intake 1 45 Plate, Clamping 1
21 Screw, Hex Flange Head 4 46 Screw, Hex Head Cap 1
22 Gasket, Connection 1 47 Tube, Water Inlet 1
23 Screw, Hex Head 12 48 Tube, Water Outlet 1
24 Cover, Intake Manifold 1 49 Hose, Plain 4
25 Gasket, Intake Mfd. Cover 1 50 Clamp, Hose 8
Air Intake System - General Information Air Intake System - Group 10
Air Intake System - General Information

The Air Intake System Group on engine coolant aftercooled engines, consists of the aftercooler assembly, aftercooler
coolant tubes and the turbocharger.
On engine coolant aftercooled engines, the aftercooler utilizes engine coolant to cool the air between the turbocharger
and combustion chambers during engine operation. The aftercooler also performs as a starting aid by warming the intake
air, if the engine is equipped with an engine coolant heater.
Refer to the Hl Series Turbocharger Shop Manual, Bulletin No. 3810321 for rebuilding the turbocharger.
The turbocharger uses exhaust gas energy to turn the turbine

wheel. The turbine wheel drives the compressor impeller which
provides compressed air to the engine for combustion. The
additional air provided by the turbocharger allows for a more
complete combustion. Therefore, more fuel can be injected to
increase the power output from the engine.
NOTE: The correct turbocharger must be used. Providing too
much additional air will increase the cylinder pressures and
4. shorten the life of the engine.
The turbine and compressor wheels and the shaft are

supported by two rotating bearings in the bearing housing.
Passages in the bearing housing direct filtered, engine oil under
pressure to the shaft bearings and thrust bearings. The oil is
used to lubricate and cool the rotating components to provide
for smooth operation. The oil then drains from the bearing
housing to the engine sump through the oil drain tube.
NOTE: An adequate supply of good, filtered oil is very
important to the life of the turbocharger.
,200pa
Air Intake System - Group 10 Turbocharger - Cleaning and Inspection for Reuse (W-01)
Turbocharger - Cleaning and Inspection

for Reuse (10-01)
Remove all carbon deposits and gasket material from
surfaces (I), (2) and (3).
A
Caution: Tape or plug all openings to prevent solvent or
steam from damaging the oil cavities in the turbocharger. A
Use solvent or steam to clean the
turbocharger. Dry with compressed air.
exterior of the
q
\ tb200eb
Inspection
Visually inspect the housings for damage.
Visually inspect the turbine wheel and compressor
(1) for fretting, cracked or broken vanes.
impeller 04iB
Turn the impeller in the direction shown with arrow (2) to
inspect the turbine shaft for freedom of rotation. The shaft
must rotate freely.
Replace damaged parts.
tb2hssd
06B
Visually inspect the mounting flange.
Cracks on the mounting flange longer than 15 mm IO.6 inch]
are not acceptable.
in+
nm
;“5
50
L15 tb900Sa
Cracks must not reach the mounting holes.
tb9OOsb
Turbocharger - Cleaning and Inspection for Reuse (10-01) Air Intake System - Group 10
Page IO-6 614 Series
Two cracks must be separated by a minimum of 6.4 mm [0.25

inch].
tb9OOsc
Part No. ST-537, Dial Depth Gauge

RI Measure the turbocharger shaft end clearance.
Push the rotor assembly away from the gauge.
@ Set the gauge on zero.
Push the rotor assembly toward the gauge and record the data.
For turbochargers with serial number before 840638:
Turbocharger Shaft End Clearance

mm in.
0.10 MIN 0.004
0.16 MAX 0.006
For turbochargers with serial number after and including

840638:
Turbocharger Shaft End Clearance

mm in.
0.03 0.001
0.08 0.003
0
Push the compressor impeller by hand toward the compressor
a9 housing.
Insert a wire feeler gauge, at the minimum clearance point,
between the impeller and the housing to measure the
@ clearance.
Record this clearance.
Intake Manifold Cover - Cleaning and Inspection for Reuse (10-02) Air Intake System - Group 10
06B
Wiih the feeler gauge in the same location, push the turbine
wheel by hand away from the compressor housing.
a
Insert a wire feeler gauge, at the same point.
Record this clearance.
Subtract the smaller from the larger clearance.
Turbine Wheel Radial Clearance

mm in.
0.21 MIN [O.OOS]
0.48 MAX [0.018]
If the radial clearance does not meet the above
specifications, the turbocharger must be rebuilt. Refer to the
l-i1 Series Turbocharger Shop Manual, Bulletin No. 3810321.
Intake Manifold Cover - Cleaning and

Remove the air intake connection.
Remove all gasket material. 0
C%
A
Use solvent or
compressed air.
steam to clean the parts. Dry with
q
\
im9cvea
Inspection
Visually inspect the intake manifold cover and intake
connection for cracks or damage. Replace damaged parts. 0
@
I im9cvsa
Aftercooler Assembly - Cleaning and

Remove all gasket material from the mounting surfaces.
Warning: When using a steam cleaner, wear protective q
\
A
q
Use solvent or steam to clean the aftercooler assembly. Dry
with compressed air. \
Aft ercooler Assembly - Rebuild (1 O-04) Air Intake System - Group 10
Inspection
04B Visually inspect the aftercooler assembly for cracks or damage.

Replace if damaged.
Pressure Test the Aftercooler Core

Install the hose, hose clamps, and solid pipe plug (1) onto the
inlet tube.
Install the hose and hose clamps (2), and air pressure gauge
(3) onto the outlet tube.
Connect the air pressure gauge to a regulated air supply.
Submerge the aftercooler in a tank of water.
If air bubbles appear, the core is damaged and the aftercooler
must be replaced.
Remove the aftercooler from the water tank.

Remove the test equipment.
Use compressed air and dry the aftercooler.
Aftercooler Assembly - Rebuild (10-04)
A
Caution: The aftercooler is a unitized assembly and cannot
be rebuilt. Any attempt to repair the aftercooler core will
reduce the coolant flow and cause future engine damage.
Refer to Aftercooler Assembly - Cleaning and Inspection for
Reuse (10-03).
at900kb
Air Intake System - Group 10 Air Crossover Tube - Cleaning and Inspection for Reuse (10-06)
Air Transfer Pipe - Cleaning and

Cleaning
A
Use solvent or steam to clean the air transfer pipe. Dry with
compressed air.
Inspection
Visually inspect the turbocharger compressor V-band outlet
and the air transfer pipe connection for dents or fretting.
Replace the turbocharger compressor housing or air transfer
0
@
pipe, if damaged.
Air Crossover Tube - Cleaning and

Cleaning
clothing and safety glasses or a face shield. Hot steam A
q
Use solvent or steam to clean the air crossover tube. Dry \
with compressed air. ,
Inspection
Visually inspect the air crossover tube for cracks or damage.
Visually inspect the hose sealing
damage. Replace damaged parts.
surfaces for pitting or 0
@
ca9tbsa
Exhaust System - Group 11
Exhaust System - Group 11

Section Contents
Page
Exhaust Manifold - Cleaning and Inspection for Reuse ............................... 11-4

Cleaning .............................................................. 11-4
Inspection ............................................................. 11-4
Exhaust Manifold - Exploded View ............................................. 11-2
Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse ................. 11-6
Cleaning.. ............................................................ 11-6
Inspection ............................................................. 11-6
Exhaust Manifold Turbocharger Mounting Stud - Replacement ......................... 11-5

Inspection ............................................................. 11-5
Installation ............................................................ 11-5
Removal .............................................................. 11-5
Exhaust System - General Information .......................................... 113

Exhaust Manifold ........................................................ 11-3
Exhaust Manifold - Exploded View Exhaust System - Group 11
Exhaust Manifold - Exploded View
Ref. No. Part Name QtY

1 Brace, Exhaust Outlet Connection 1
3 Connection, Exhaust Outlet 1
4 Clamp, V Band 1
5 Pipe, Plug 1
6 Gasket, Turbocharger 1
7 Stud 4
8 Nut 4
9 Manifold, Exhaust 1
11 Gasket, Manifold 6
12 Lockplate 12
Exhaust System - Group 11 Exhaust System - General Information
614 Series Page 1 l-3
Exhaust System - General Information

The exhaust system group consists of the exhaust manifold, turbocharger mounting studs, and exhaust outlet connection.
Any repairs relating to the exhaust pipe or muffler should be directed to the original equipment manufacturer.
Exhaust Manifold
The engine uses a “pulse-type” exhaust manifold with a divided turbocharger entry passage (exhaust manifold outlet).
The naturally aspirated engine uses the same manifold for parts commonality.
Exhaust Manifold - Cleaning and Inspection for Reuse (1 l-01) Exhaust System - Group 11
Exhaust Manifold - Cleaning and

Inspection for Reuse (1 I-01)
Cleaning
Use a wire brush or 240 grit emery cloth to remove the carbon
from the gasket sealing surfaces.

Use steam to clean the manifold. Dry with compressed air.
xm900eb
Inspection
Visually inspect the manifold for cracks or damage.
Visually inspect the turbocharger mounting stud holes for
damaged threads.
Replace the manifold, if damaged.
xm9OOsa
Place a straight edge across the exhaust ports.

Inspect the mounting surfaces for flatness.
If these surfaces are not within the flatness specifications,
replace the manifold.
Exhaust Manifold Mounting Surface Flatness

mm in.
0.20 MAX 0.008
Turbocharger Mounting Flange Flatness
mm in.
0.13 MAX 0.005
Exhaust System - Group 11 Exhaust Manifold Turbocharger Mounting Stud - Replacement (1 l-02)
614 Series Page 1l-5
Exhaust Manifold Turbocharger Mounting

Stud - Replacement (1 I-02)
Removal
Apply penetrating
mounting stud to
instructions.
oil to the base of the turbocharger
be removed. Follow the manufacturer’s %
0
Use a standard stud extractor or two nuts locked together to

remove the turbocharger mounting stud(s) from the manifold.
xm90Oma
Inspection
Visually inspect for damaged threads in the turbocharger
mounting stud holes.
Visually inspect the manifold for cracks or damage.
xm900sb
Installation
Use precoated turbocharger mounting studs or apply a thin
coating of nickel based, high temperature, anti-seize
compound to the coarse threads of the stud.
Install the studs in the mounting flange.
Use two mounting nuts locked together to tighten the studs.
Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse 111-03)
. , Exhaust System - Group 11
Page 11-6 614 S&es
Exhaust Manifold Outlet Connection -

Cleaning and Inspection for Reuse
(1 I-03)
Cleaning
\
q
Use a wire brush to remove carbon from the v-band clamp
mounting grooves.

\
q
Use steam to clean the outlet connection.
air.
Dry with compressed
Inspection
Visually inspect the outlet connection for cracks or damage to
4B
0 the mounting surface or clamp grooves. Replace any part that
is cracked or damaged.
Air Equipment - Group 12
Air Equipment - Group 12
For air equipment service information see chassis shop manual.

Electrical Equipment - Group 13
Electrical Equipment - Group 13
For electrical equipment service information see chassis shop manual.

Engine Testing - Group 14

Section Contents
Page
Blowby Measurement ........................................................ 14-7
Engine Dynamometer Test - Engine Run-In ....................................... 14-17
Engine Dynamometer Test - Installation of the Engine ................................. 14-9
Engine Dynamometer Test - Performance Checking ................................. 14-21
Engine Painting ........................................................... 14-26
Engine Run-In Procedure - “In-Chassis” ......................................... 14-24
Engine Run-In - General Procedures ............................................. 14-8
Engine Storage - Long Term .................................................. 14-29

Engine Removal from Long Term Storage ........................................ 14-32
Engine Storage - Short Term ................................................. 14-27

Engine Removal From Short Term Storage ........................................ 14-29
Engine Testing - Component Identification and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Engine Testing - General Information ............................................. 14-5

Engine Dynamometer Run-in .................................................. 14-5
In-Chassis Run-in .......................................................... 14-5
Engine Testing i General Specifications ........................................... 146
Engine Testing - Service Tools ................................................. 14-2
Fuel Injection Pump - Idle Speed Adjustment ...................................... 14-25

RSVGovernor ........................................................... 14-25
RQV and RQVK Governor ................................................... 14-26
General Engine Test Procedure - In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23

Engine Testing - Service Tools Engine Testing - Component Identification and Diagrams - Group 14
Engine Testing - Service Tools
Check the fuel filter restriction during the engine performance

test. Hose adapter, Part No. ST-434-2 and vacuum gauge, Part
No. ST-434-12, are used to perform the test.
Used with the blowby check tool to measure engine crankcase
Used to measure the engine intake manifold pressure.
Used to measure lubricating oil pressure.
Used to measure engine speed (RPM).
Used with manometer, Part No. ST-1 111-3, to measure the

engine crankcase pressure.
Engine Testing - Group 14 Engine Testing - Component Identification and Diagrams
Engine Testing - Component Identification and Diagrams

The following illustrations contain information about engine components, filter locations, drain points and access locations
for instrumentation and engine controls.
The information and configuration of components shown in these illustrations are of a general nature. Some component
locations will vary depending on applications and installations.
High Pressure
W[inch]NPTF (Air)
Fuel Lines
Front Lifting
Bracket Rear Lifting
) Bracket
Fuel
Injection -
Pump
%x lG[inch]UNF
Tap for Magnetic
Pick-up
Air
Compressor
Front Engine
Mounting Bracket
Fuel Pump Side View

Engine Testing - Component Identification and Diagrams Engine Testing - Group 14
Turbocharger Turbocharger
Turbocharger
Exhaust Outlet Water Outlet
Connection
\ Lubricating Oil
Provision for
Coolant Heater -
Provision for -
Cab Heater Pressure (before
Turbocharger
Oil Drain
Turbocharger Side View

Engine Testing - Group 14 Engine Testing - General Information
614 Series Page 145
Engine Testing - General Information

This section outlines engine testing and engine run-in recommendations for 614 Series engines. All engines must be run-
in after a rebuild or a repair involving the replacement of one or more piston ring sets, cylinder liners or cylinder kiis.
A Caution: Incorrect or insufficient break-in of the piston rings will lead to early oil consumption or high
blowby complaints. Adherence to these run-in guidelines will allow the full durability of new rings to be
realized.
The engine test is a combination of an engine run-in and a performance check. The engine run-in procedure provides
an operating period that allows the engine parts to achieve a final finish and fii. The performance check provides an
opportunity to perform final adjustments needed to optimize the engine performance.
An engine test can be performed by using either an engine dynamometer or a chassis dynamometer. If a dynamometer
is not available, an engine test must be performed in a manner that simulates a dynamometer test.
Check the dynamometer before beginning the test. The dynamometer must have the capability to test the performance
of the engine when the engine is operating at the maximum RPM and horsepower range (full power).
Before running the engine, make sure the engine is filled with the proper coolant and the lubricating oil system is filled
and primed.
The engine crankcase pressure, often referred to as engine blowby, is an important factor that indicates when the piston
rings have achieved the correct finish and fit. Rapid changes of blowby or values that exceed specification more than 50
percent indicate that something is wrong. The engine test must be discontinued until the cause has been determined and
corrected.
In-Chassis Run-In
The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. However, light
load/high speed operation must be avoided during the run-in period. The following in-chassis run-in guidelines are
recommended for 614 Series engines after a repair involving replacement of one or more of the piston ring sets, cylinder
liners, or cylinder kiis where engine or chassis dynamometer or load bank run-in cannot be performed.
SRT 14-704, Engine - Run-in and Test (in-Chassis), provides time for in-chassis run-in when there is no other way to
perform the run-in (chassis dynamometer, load bank or portable dynamometer) and the engine will be applied in a high
speed or low load operation immediately after the engine is returned to service.
Engine Dynamometer Run-in
This is the preferred method of run-in for engines that have been rebuilt out-of-chassis. It is not practical, nor
recommended, that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair has
been performed in-chassis. SRT 14-701, Engine - Run-In and Test (Engine Dynamometer) provides the time for this work.
There is no requirement, nor is it recommended for an engine that has been run-in and tested on an engine dynamometer
to be run-in again after it has been reinstalled in the vehicle or equipment.
Engine Testing - General Specifications Engine Testing - Group 14
Engine Testing - General Specifications

NOTE: due to variations in ratings of different engine models, refer to the specific engine data sheet for the particular
engine model being tested.
Maintain the following limits during an engine run-in on a dynamometer:
Intake Restriction: (Maximum)

l Clean Filter ................................................. 380 mm H,O [15 in. H,O]
. Dirty Filter .................................................. 635 mm H,O [25 in. H,O]
Air Inlet Temperature (Maximum) ................................................ 38°C [lOOoF]
Exhaust Temperature ...................................................... 700” C [1290” F]
Exhaust Back Pressure: (Maximum) ........................................ 76 mm Hg [3.0 in Hg]
Smoke:
l Bosch Smoke Meter (Maximum) ............................................... 2.5 Units
. Celesco Smoke Meter (Maximum) ............................................ 4% Opacity
Coolant Temperature (Maximum) ............................................... 100” C [212“ F]
Lubricating Oil Temperature (Maximum) ......................................... 126.6” C [260” F]
Lubricating Oil Pressure:

. Low Idle (Minimum Allowable) ........................................... 69 kPa [lo psi]
l Rated Speed (Minimum Allowable) ......................................... 207 kPa [30 psi]
Fuel Filter Restriction - Dirty Filter (Maximum) ............................... 89 mm Hg [3.5 in. H,O]
Fuel Return Restriction (Maximum) .............................................. 35 kPa [5 psi]
Blowby: *New (L/Min) *Worn (L/Min)

l 614 (Maximum) (Rectangular intermediate ring) 44 88
l 614T (Maximum) (Rectangular intermediate ring) 113 226
l 614TA (Maximum) (Rectangular intermediate ring) 113 226
l (All engines with reverse twist intermediate ring) 145 290
* Blowby checking tool, Part No. 3822566, has a special 7.67 mm [0.302 in] orifice that must be used to obtain an
accurate reading.
Refer to the blowby conversion chart on the following page to convert liters/minute into inches/water.
Engine Testing - Group 14 Blowby Measurement
Blowby Measurement
Blowby is generally recorded in liters/minute.
Install the Part No. 3822566, Engine Blowby Tool, to the
crankcase breather tube in the valve cover.
Install a water manometer to the engine blowby tool.
Use the Bloby Conversion Chart to conver the manometer
reading to liters/minute.
NOTE: A pressure gauge can be used to record the engine
blowby.
Minimum Gauge Capacity: 1270 mm H,O [50 in H,O]
Blowby Conversion Chart (7.67 mm

[0.302 in]) Orifice
Inches of
Liters/Minute
Water
1 50
2 84
3 103
4 119
5 133
6 145
7 155
8 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17 222
18 226
19 229
20 235
21 239
22 242
23 246
24 248
Engine Run-In - General Procedures Engine Testing - Group 14
Engine Run-In - General Procedures
A
Caution: Refer to Engine Test - General Specifications, page
14-8, before operating the engine to avoid internal
component damage.
Caution: The lubricating oil system must be pressurized
before operating the engine to avoid internal component
damage.
NOTE: The amount of time specified for the following engine
run-in phases are minimums.
The engine can be operated for longer periods of time at each
operating range or phase with the exception of engine idling
which must be kept to 10 minutes or less.
Start the engine and idle for initial check.

NOTE: Avoid long idle periods. Operate the engine at low idle
only long enough (10 minutes maximum) to check for correct
oil pressure and any fuel, oil, water, or air leaks.
NOTE: Do not operate the engine at idle speed longer than
specified during engine run-in. Excessive carbon formation will
occur and cause damage to the engine.
NOTE: To avoid internal component damage, do not allow the

engine speed to exceed 1,000 RPM before run-in.
0
While the engine is idling, listen for unusual noises; watch for
4B coolant, fuel, and lubricating oil leaks; and check for correct
engine operation in general.
NOTE: Repair all leaks or component problems before
continuing the engine run-in.
Engine Testing - Group 14 Engine Dynamometer Test - Installation of the Engine (1401)
Caution: Do not shut off the engine immediately after the

run-in is completed. Allow the engine to cool by
operating at low idle for a minimum of 3 minutes to avoid
internal component damage.
A
Caution: On engines equipped with a wet clutch flywheel

housing, it will be necessary to replace the rear
crankshaft oil seal after engine testing. If the engine is
operated with a dry housing, the wet clutch oil seal will
A
be destroyed.
Engine Dynamometer Test - Installation

of the Engine (14-01)
Use engine lifting fixture, Part No. 3822512, to install the e
engine to the test stand. Align and connect the
dynamometer. Refer to the manufacturer’s instructions for
aligning and testing the engine.
NOTE: Make sure the dynamometer capacity is sufficient to
permit testing at 100 percent of the engine rated horsepower.
If the capacity is not enough, the testing procedure must be
modified to match the restrictions of the dynamometer.
Install the coolant temperature sensor.

Minimum Gauge Capacity: 107°C [225”F]
Engine Dynamometer Test - Installation of the Engine (M-01) 614 Series
Page 14-10
Connect the coolant supply to the water inlet connection (1).
Connect the coolant return to the water outlet connection (2).
Install the drain plugs, close all the water drain cocks, and
make sure all the clamps and fiiings are tight.
Connect the vent tube to the vent connection on the thermostat
housing.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
0OK
0
Inspect the engine for coolant leaks at connections,
a!9 plates, and plugs. Repair as necessary.
The intake air piping must be plumbed through #an qb

aftercooler to control the temperature of the intake arr durrng (9
4~
the run-in procedure. Rig an aftercooler beside the engrne,
and plumb the intake pipes from the turbocharger, through
the afiercooler and back to the intake manifold.
Use a temperature gauge (1) to measure the intake manifold
temperature.
NOTE: Maintain the intake manifold air temperature at 33°C
[15O”F] or below during the dynamometer testing or run-in; if
manifold temperature exceeds this limit, terminate the test
and idle the engine to let it cool down. Do not idle more
than 10 minutes. Testing can resume when the intake air
temperature can be maintained below 66°C 1150” F]. Under
no circumstances is the intake manifold air temperature
allowed to exceed 77°C [170” F].
Connect a water manometer (2) to the turbocharger air inlet

pipe to test air restriction.
NOTE: A vacuum gauge can be used in place of the water
manometer.
Minimum Gauge Capacity: 760 mm H,O [30 in. H,O]
Connect a mercury manometer (3) to a straight section of @A

the exhaust piping near the turbocharger outlet to check 4~
exhaust restriction.
NOTE: A pressure gauge can be used in place of the
mercury manometer.
Minimum Gauge Capacity: 254 mm Hg [lo in. Hg]
Remove the pipe plug from the bottom of the oil cooler and @@A
install the lubricating oil temperature sensor. as9
Minimum Gauge Capacity: 150°C [3OO”F]
Engine Dynamometer Test - Installation of the Engine (14-01) Engine Testing - Group 14
Page 14i2 614 Series
Attach the lubricating oil pressure sensor to the main oil rifle
drilling in the cylinder block.
Minimum Gauge Capacity: 1034 kPa [150 psi]
Caution: To avoid internal component damage, the

lubricating oil system must be pressurized before operating
the engine after any internal engine repairs or extended
engine storage (beyond 6 months).
To pressurize the system using external pressure, connect the
supply to the lower pipe plug hole in the upper part of the oil
cooler cover as illustrated.
Use a pump capable of supplying 210 kPa [30 psi] continuous

pressure.
Use clean 15W-40 engine oil to pressurize the system until the
oil pressure registers on the gauge.
Remove the oil supply tube, and install the plug.
Make sure the lubricating oil has had time to drain to the pan
and fill the engine to the “High” mark as measured on the
dipstick.
NOTE: If the dipstick is new, it must be correctly calibrated.
Refer to Lubricating Oil Dipstick - Calibration (7-07).
Engine Testing - Group 14 Engine Dynamometer Test - Installation of the Engine (14-01)
614 Series - _ Page 14-13
If an external pressure pump is not available, pressurize the

lubricating system according to the following procedure:
Fill the engine with oil to the “High” level mark on the
dipstick.
Disconnect the turbocharger lubricating oil supply tube.

Pour 50 cc to 60 cc [2.0 fl. oz. to 3.0 fl. oz.] of clean
15W-40 engine oil into the turbocharger oil supply hole.
Connect the oil supply tube to the turbocharger.
Remove the lubricating oil filter and fill with clean 15W-40
engine oil. 0
%
Screw the filter onto the filter head fitting until the gasket
contacts the filter head surface.
($#A
Use oil filter wrench, Part No. 3375049, to tighten the filters 4~
an additional 3/4 to 1 turn.
Make sure the fuel is shut off by removing the wire from the
fuel solenoid or the mechanical fuel shutoff is in the “OFF”
position. This is necessary to prevent the engine from
starting during the oil rifle pressure charging operation.
Engine Dynamometer Test - Installation of the Engine (1401) Engine Testing - Group 14
Page lQi4 614 Series
A Caution: Do not crank the starting motor for periods longer

than 30 seconds. Excessive heat will damage the starting
motor.
Crank the engine until the oil pressure gauge indicates system
pressure.
NOTE: Allow 2 minutes between the 30-second cranking
periods so the starting motor can cool.
NOTE: If pressure is not indicated, find and correct the
problem before continuing.
Allow the lubricating oil to drain into the oil pan, and measure
the oil level with the dipstick.
Add oil as necessary to bring the level to the “High” level
mark.
Lubricate the gasket on the fuel filter with clean 15W-40 engine
oil.
Fill the fuel filter with clean No. 2 diesel fuel.
Caution: To prevent air leaks, make sure the filter is
A installed tightly but not overtightned. Mechanical

overtightening can distort the threads or damage the filter
element seal.
Install the filter as specified by the filter manufacturer. If there
are no instructions, refer to the following guidelines.
Screw the fuel filter onto the filter head until the gasket
contacts the filter head surface.
Tighten the filter an additional l/2 to 3/4 turn.
+ Vi to % Turn
8 mm
NOTE: Manual ventina is reauired if the fuel filter is not
properly filled prior to iiLstallatidn.
Open the vent screw.
Operate the plunger on the fuel transfer pump until the fuel
flowing from the fitting is free of air.
Tighten the vent screw.
Check the voltage rating on the fuel pump solenoid before

connecting the electrical wires to it. Make sure the voltage o
supply matches that of the fuel pump solenoid. @
Attach the throttle control rod onto the fuel pump throttle @
lever. @
To determine the amount of turbocharger boost, remove the

l/4 inch pipe plug in the cylinder head and install the intake
manifold pressure sensor or pressure aauae.v v. Part No.
ST-1273. ’
Minimum Gauge Capacity: 1905 mm Hg [75 in. Hg]
Checking Tool, Part No. 3822566

For accurate engine crankcase blowby measurement, insert Ezl
blowby checking tool, Part No. 3822566, in the crankcase
breather vent. e
Connect a water manometer to the blowby tool. A pressure O$
* *
gauge can be used in place of the manometer.
Minimum Gauge Capacity: 1270 mm H,O [50 in. H,O]
Engine Dynamometer Test - Installation of the Engine (1401) Engine Testing - Group 14
Page 14-16 614 Skies
To measure fuel filter restriction, connect vacuum gauge, Part

No. ST-434, to the fuel transfer pump inlet line.
Minimum Gauge Capacity: 760 mm Hg 130 in. Hg]
To be able to unload the compressor, connect a source of

compressed air to the unloader (1). This air line must contain
a valve between the source and the unloader.
NOTE: All air compressors must be loaded during engine
run-in. All air compressors must be unloaded during the
engine performance check.
NOTE: The compressed air load in the accompanying
illustration must be attached to the air compressor outlet (2).
To provide a load on the air compressor, connect an air tank

to the compressor outlet (2), using steel tubing or a high
temperature hose (1).
Install an air regulator (3) that can maintain tank air pressure of
345 kPa to 517 kPa [50 psi to 75 psi] at both the minimum
and the maximum engine speed.
Hose Temperature (Minimum): 260°C [5OO”F]
Check the voltage rating on the starting motor before installing

the electrical wiring.
Attach electrical wires to the starting motor and the batteries,
if used.
NOTE: If another method of starting the engine is used, follow
the manufacturer’s instructions to make the necessary
connections.
Engine Testing - Group 14 Engine Dynamometer Test - Engine Run-in (14-02)
Engine Dynamometer Test - Engine

Run-In (14-02)
The engine run-in period allows the tester to detect assembly
errors and to make final adjustments needed for performance
that meets specifications.
0
@
NOTE: The amount of time specified for the following engine

run-in phases are minimums. Additional time can be used at
each phase except engine idle periods, if so desired.
Caution: On engines equipped with a wet clutch flywheel

housing, it will be necessary to replace the rear
crankshaft oil seal after engine testing. If the engine is
operated with a dry housing, the wet clutch oil seal will
A
be destroyed.
Measurements from these indicators and gauges must be

observed closely during all phases of the engine run-in
period. Refer to page 14-6 for specifications and acceptable
readings.
Coolant Out Lube Oil

Temp. Temp. B’owby eg8gasd
0a!!3
To correctly evaluate the engine performance, this additional
measurement must be observed during engine run-in phases.
Intake Manifold
Pressure
(Turbocharger Boost)
Engine Dynamometer Test - Engine Rim-In (14-02) Engine Testing - Group 14
Page 1418 814 Series
It is a good practice to observe these measurements even if

engine performance meets specifications. If engine performance
does not meet specifications, these measurements can indicate
possible reasons for under-performance.
Fuel in Restriction Exh. Back Pres. Coolant

Pressure
@ qJ
Air Inlet Restriction Fuel Drain Pres. oigoow
Engine performance specifications and fuel system calibration

values are listed in the Engine Diagnostic Manual.
NOTE: Fuel pump calibration changes must be performed by
an authorized ADS shop.
A Caution: Do not crank the engine for more than 30

seconds. Excessive heat will damage the starting motor.
Crank the engine and observe the oil pressure when the engine
starts. If the engine fails to start within 30 seconds, allow the
starting motor to cool for 2 minutes before cranking the engine
again.
A Caution: If the lubricating oil pressure is not within

specifications, shut off the engine immediately. Either
excessively low or excessively high oil pressure will cause
engine damage.
Engine oil pressure must be between 69 kPa and 310 kPa [lo
0
@B psi and 45 psi] at 700 RPM.
Correct the problem if the oil pressure is not within

specifications.
Engine Testing - Group 14 Engine Dynamometer Test - Engine Run-In (1402)
614 Series Page 1419
Caution: Do not operate the engine at idle speed longer

than specified during engine run-in. Excessive carbon
formation will cause damage to the engine.
A 3 to 5 Minutes
Operate the engine at approximately 700 RPM for 3 to 5
minutes.
NOTE: If the idle speed is incorrect, refer to Procedure 14-06
for adjustment information. _’
0a!3
Listen for unusual noises; watch for coolant, fuel, and
lubricating oil leaks; and check for correct engine operation
in general.
NOTE: Repair all leaks or component problems before
continuing the engine run-in.
Move the throttle. to obtain 1,200 RPM engine speed, and set
the test load to 25 percent of the rated load.
Operate the engine at this speed and load level until the 0 1200
coolant temperature is 70°C [16O”F]. Check all gauges and
record the data.
NOTE: Do not proceed to the next step until a steady .. @@>
blowby reading is obtained.
Test Load
@“”
@
70°C [160°F]
a 0,802v,
1
Open the throttle to the speed at which peak torque occurs,
and adjust the dynamometer load to 50 percent of rated
load. Operate the engine at this speed and load level for 2
minutes.
Torque Peak
Check all gauges and record the data.
NOTE: Do not proceed to the next step until blowby is 2x (Test Load)
stable and within specifications. (50% Rated Load)
2 Minutes
Engine Dynamometer Test - Engine Run-In (14-02) Engine Testing - Group 14
0
With the engine speed remaining at torque peak RPM, increase
a3 the dynamometer load to 75 percent of rated load. Operate the
engine at this speed and load level for 2 minutes. Check all
Torque Peak gauges and record the data.
NOTE: Do not proceed to the next step until blowby is stable
3x (Test Load) and within specifications.
(75% Rated Load)
2 Minutes
Move the throttle lever to its fully opened position, and increase
the dynamometer load until the engine speed is at torque peak
RPM. Operate the engine at this speed and load level for 10
minutes or until the blowby becomes stable and within
Full Throttle
specifications.
Torque Peak
a9
0
Maximum Load
10 Minutes
Reduce the dynamometer load until the engine speed increases

to the engine’s rated RPM.
Full Throttle Operate the engine at rated RPM for 5 minutes.
0@
Rated Check all gauges and record the data.
Maximum Load
at Rated Speed
5 Minutes
oi804vk
Caution: Shutting off the engine immediately after operating

at full load will damage the turbocharger and internal
A components. Always allow the engine to cool before
shutting it off.
Remove the dynamometer load completely and operate the
engine at 700 RPM for 3 to 5 minutes. This period will allow the
turbocharger and other components to cool.
NOTE: If the idle speed is incorrect, refer to Procedure 14-06
for adjustment information.
Engine Testing - Group 14 Engine Dynamometer Test - Performance Checking (1403)
Shut off the engine.
I I
oi802vx 1
Make sure all instrumentation is removed

the engine from the engine dynamometer.
before removing
c% 0
Engine Dynamometer Test - Performance

Checking (14-03)
Make sure the air compressor will be unloaded during the
performance check. @3
0
Apply regulated air pressure of 655 kPa [95 psi] to the air
compressor unloader (1).
Caution: Do not crank the engine for more than 30

seconds. Excessive heat will damage the starting motor. A
Crank the engine and observe the oil pressure when the
engine starts. If the engine fails to start within 30 seconds,
allow the starting motor to cool for 2 minutes before
cranking the engine again.
Engine Dynamometer Test - Performance Checking (1403) Engine Testing - Group 14
Caution: If the lubricating oil pressure is not within
A specifications, shut off the engine immediately.

excessively low or excessively high oil pressure will
engine damage. Correct the problem if oil pressure
Either
cause
is not
within specifications.
Engine oil pressure must be between 69 kPa and 310 kPa [lo
psi and 45 psi] at approximately 700 RPM.
Make sure the engine is at operating temperature.

Move the throttle lever to the “FULL OPEN” position. Adjust the
dynamometer load until the engine maintains the rated RPM.
Allow the readings to stabilize. Read the horsepower.
Check all the gauges and record the readings.
NOTE: The horsepower reading will not be accurate if the
lubricating oil temperature and fuel temperature are not within
specifications.
Lubricating Oil Temperature: MIN WC [l WF]
Fuel Temperature: MAX 32°C [W’F]
A Caution: Do not shut off the engine immediately after it has

been loaded. It must be allowed to sufficiently cool.
3 to 5 Minutes Remove the dynamometer load completely and operate the
engine at idle speed for 3 to 5 minutes. This will allow the
turbocharger and other components to cool.
Idle periods longer than 5 minutes are to be avoided.
Shut off the engine after the cool-down period.
oi802vx
Engine Testing - Group 14 General Engine Test Procedure - In Chassis (14-04)
NOTE: If the horsepower is below specifications, remove the

fuel pump and have the pump checked.
NOTE: The low idle speed is an external adjustment and can
be adjusted with the pump installed. Refer to Procedure e
14-06. All other adjustments, such as; no-air setting and
governor break speed are internal which requires pump
removal for adjustment.
Remove all test instrumentation. Remove the engine from the

dynamometer.
NOTE: If the engine is to be stored temporarily and does
not have permanent-type antifreeze, it is necessary to drain e
all coolant. Drain locations are identifed on the engine
diagrams, pages 143 and 14-4.
Prepare the engine for Engine Painting (14-67) or Engine
Storage (14-08) or (14-09).
General Engine Test Procedure - In

Chassis (14-04)
A
Caution: the following procedure assumes that the
lubricating oil and fuel systems were correctly primed, the
dipstick calibrated, and the engine filled to the correct
levels with oil and coolant during installation of the
engine into the chassis. If these sytems were not serviced
during installation of the engine, refer to Engine
Dynamometer Test - Installation of the Engine (1401) for
instructions on priming the lubricating oil and the fuel
systems and calibrating the dipstick. Refer to the machine
Operation and Maintenance Manual for instructions on
filling the lubricating oil and the cooling systems.
Perform the following tests before the Engine Run-in

Procedure (14-65) is started.
l Coolant Pressure
l Fuel Inlet Restriction
l Lubricating Oil Pressure
l Intake Manifold Pressure
l Intake Air Restriction
l Crankcase Gasses (Blowby)
Test procedures and values are documented in the Engine
Diagnostic Manual.
Engine Dynamometer Test - Performance Checking (14-03) Engine Testing - Group 14
Page 14-24 614 Skies
Engine Run-In Procedure - “In-Chassis”

(14-05)
A Caution: Refer to - General Engine Test Procedures - In

Chassis (1404) before operating the engine to avoid
internal component damage.
Operate the engine as follows during the first 3 hours after
rebuild:
Hours Hour
1. Do not idle the engine for more than 5 minutes at any

one time.
2. Operate the engine at 75 percent throttle while loaded.
m
m Hours Hours
Hours Hours 0iVXvy
3. Do not operate the engine at rated speed (RPM) and full

load for more than 5 minutes at any one time.
iours Hours 0ilOOvz
Change the lubricating oil and filter after 800 km [500 miles] or
20 hours of operation. Refer to the Operation and Maintenance
Manual.
Engine Testing - Group 14 Fuel Injection Pump - Idle Speed Adjustment (14-06)
Fuel Injection Pump - Idle Speed

Adjustment (14-06)
RSV Governor
idle adjustment for industrial engines requires the setting of
both the low idle screw (1) and the bumper spring screw (2)
on the fuel injection pump.
19 mm, Screwdriver, Tachometer

First, loosen the locknut and back out the bumper spring
screw on the fuel injection pump until there is no change in
RI
engine speed.
The speed should drop 20-30 RPM as the bumper spring
screw is backed out.
13 mm, Screwdriver, Tachometer

Loosen the locknut and adjust the low idle screw to 20-30
RPM less than the desired speed. Turn the low idle screw
counterclockwise to decrease RPM; clockwise to increase
RPM. Tighten the low idle screw locknut.
Turn the bumper spring screw clockwise until the desired

idle speed is obtained. Tighten the bumper spring screw
locknut.
Torque Value: 8 N*m 172 in-lb]
Engine Painting (1407) Engine Testing - Group 14
RQV and RQVK Governor

10 mm, Screwdriver and Tachometer
Low idle adjustment on automotive fuel injection pumps
requires setting of the low idle stop screw.
Loosen the low idle screw locknut and turn the low idle screw
counterclockwise to raise the RPM; clockwise to decrease the
RPM. Tighten the low idle screw locknut.
Engine Painting (14-07)

Remove all belts from the engine.
Cover the following parts of the engine with plastic caps or
tape:
l Exhaust and intake openings
l Electrical components
l Fuel inlet and drain connections
l Any exposed fittings, threads, and electrical wire
terminals

Use steam to clean the engine. Dry with compressed air.
NOTE: Make sure all engine surfaces are clean and dry before
painting the engine.
Protect the following components from the paint:

l All dataplates; engine, turbocharger and fuel pump
l Exhaust manifold
l Turbocharger turbine housing
l Flywheel
l Flywheel housing transmission mounting surface
Engine Testing - Group 14 Engine Storage - Short Term (14-08)
Paint the engine.
Engine Storage - Short Term (14-08)

NOTE: This procedure describes the correct method for
preparing an engine for short-term (1 to 6 months) storage.
Be sure the cooling system and lubricating oil system are
properly filled.
Operate the engine at high idle until the coolant temperature
reaches 70” C [ 160” F] .
Shut off the engine. High Idle 7o”c
[16OOF]
oi803vs
Remove the fuel. tube to the engine fuel filter (1) and the
injector fuel return tube (2).
NOTE: Fuel system preservative oil must meet Federal
Specification W-L-8OOC. (Example: Daubert Chemical
NoxRust No. 518).
Fill two containers, one with diesel fuel and the other with
the preservative oil. Put both fuel tubes into the container of
diesel fuel.
Start the engine and run until it is operating smoothly, then

put the fuel supply tube into the container of preservative oil.
Remove the injector return tube from the diesel fuel
container. When preservative oil flows from the tube, shut off
the engine.
Connect the fuel supply tube to the fuel filter, and put a cap
on all other fuel tubes.
Engine Storage - Short Term (14-08) Engine Testing - Group 14
Drain the lubricating oil pan, oil filters, and fuel filter.
Install the drain plug into the oil pan, and install new filters.
Tighten according to specifications.
Disconnect the electrical wires from the fuel pump solenoid.
Drain the coolant passages and jackets.

NOTE: It is not necessary to drain the coolant if it is a
permanent-type antifreeze with a rust inhibitor. Do not drain the
coolant if the engine is installed in a vehicle.
Visually check the engine and cover all openings with tape to
prevent dirt and moisture from entering.
Install a WARNING tag which alerts others of no oil in the
engine and that it must not be started.
Engine Testing - Group 14 Engine Storage - Long Term (M-09)
Store the engine in a dry area of even temperature.

Rotate the crankshaft two to three revolutions every 3 to 4
weeks by using the engine barring tool, Part No. 3377371, to SMTWTFS
rotate the crankshaft.
oi90ln
Engine Removal From Short Term Storage

Remove the
WARNING tag.
tape from all openings and remove
Refill the oil filters with clean 15W-40 engine oil, and
the
c%
0
pressurize the lubrication system. Refer to Engine

Dynamometer Test - Engine Run-in (14-02).
Use clean No. 2 diesel fuel to flush the preservative oil from
the fuel system, and fill the fuel filters again.
Connect the electrical wiring to the fuel pump solenoid. e

Prime and vent the fuel system. Refer to page 14-15.
Engine Storage - Long Term (14-09)

This procedure describes the correct method of preparing an
engine for long-term (6 to 24 months) storage.
If the engine has been stored for 24 months, the cooling
system must be flushed with a solvent. Repeat the flushing
procedure a second time.
Engine Storage - Long Term (1409) Engine Testing - Group 14
Be sure the cooling system and lubricating oil system are

properly filled.
Operate the engine at the high idle throttle position until the
coolant temperature is 70°C [18O”F].
Shut off the engine.
Drain the lubricating oil pan. Install the drain plug, and fill the
oil pan to the “High” level mark on the dipstick with
preservative oil.
NOTE: Lubricating system preservative oil must meet Military
Specification MIL-L-21280 Type E30-1 SAE 30. (Example: Shell
88202).
Disconnect the fuel supply tube at the fuel filter (1) and the
injector fuel return tube (2).
NOTE: Fuel system preservative oil must meet Federal
Specification W-L8OOC. (Example: Dauber-t Chemical NoxRust
No. 518).
Fill two containers, one with diesel fuel and the other with
preservative oil. Put both fuel tubes into the container of diesel
fuel.
Start the engine and run until it is operating smoothly, then put
the fuel supply tube into the container of preservative oil.
Remove the injector return tube from the diesel fuel container.
When the preservative oil flows from the tube, shut off the
engine.
Connect the fuel supply tube to the fuel filter, and put a cap on
the ends of all the other fuel tubes.
Engine Testing - Group 14 Engine Storage - Long Term (U-09)
Drain the preservative oil from the lubricating oil pan and oil
filters. Install the drain plug. Tighten according to
specifications.
Drain and flush the cooling system, using a water-soluble
rust inhibitor.
Remove the aftercooler assembly and the exhaust manifold.

Refer to Engine Disassembly (00-01).
Spray preservative oil into the intake and exhaust ports of
the cylinder head and into the aftercooler housing and the
exhaust manifold.
Install the aftercooler assembly and exhaust manifold. Refer
to Engine Assembly (00-02).
Remove the valve cover, and spray the rocker levers, valve
springs, valve stems, valve guides, and push rods with 0
a
preservative oil. Install the valve cover.
Spray preservative oil into the intake port of the air
compressor and on all exposed metal surfaces that are not
painted.
NOTE: Use a preservative compound that meets Military
Specification MIL-C16137C Type P-2 Grade 1 or 2.
Cover all openings with heavy paper and tape to prevent

entrance of dirt and moisture.
Put a WARNING tag on the engine which contains the @
following information: @
0 Date the engine was prepared for storage.
l Crankshaft must not be rotated.
0 Coolant has been drained.
0 Engine must not be operated.
Store the engine in a dry area of even temperature.
Engine Removal from Long Term Storage

Remove the paper and the tape from all openings.
Remove the WARNING tag.
Flush the fuel system with clean diesel fuel to remove

preservative oil.
Rotate the water pump to make sure it has not rusted in place.
Rotate the crankshaft two complete revolutions to make sure

the piston rings are free and no foreign objects are in the
engine.
Engine Testing - Group 14 Engine Storage - Long Term (1409)
614 Series Page 1433
Remove the intake manifold cover or aftercooler and visually

inspect the lower valve stem area for presence of rust. An 0
C%
0a3
accumulation of rust requires disassembly and rebuild of the
cylinder head.
Install all drive belts.
Remove a plug from the main oil rifle drilling and flush the
preservative oil from the engine by pumping 3.8 liters [l.O
gallon] of light mineral oil into the oil rifle. Rotate the
crankshaft three or four revolutions as the engine is being
flushed. Install the plug.
Remove the oil drain plug and allow the mineral oil to drain
from the engine. 0
C%
Remove the lubricating oil filter. Install a new filter according to

the manufacturer’s specifications.
Pressure fill the engine with 15W-40 lubricating oil through the
pipe plug hole on the top side of the oil cooler housing directly
below the turbocharger oil supply connection. Use 207 kPa [30
psi] to pressure fill the system with a minimum of 3.6 liters [l
U.S. gal.].
Caution: Disconnect the fuel solenoid or position the shut

down lever in the “STOP” position to make sure the engine
does not start when the crankshaft is rotated.
Use the starter to rotate the engine for a maximum of 30
seconds, with two minute intervals, until oil pressure registers
on the lubricating oil gauge.
Fill the oil pan to the “High” mark on the dipstick.

Engine Testing - Group 14 Engine Storage - Long Term (14-09)
614Series Page 14-35
Install a new coolant filter. Fill the cooling system with a
mixture of 50% water and 50% ethylene-glycol type
antifreeze.
Adjust the valve clearance. Refer to Engine Assembly (00-02). e
Tighten all capscrews, plugs and fiiings as necessary. Refer e

to the Specifications section.
Instruments and Controls - Group 15
Instruments and Controls - Group 15
For instruments and controls equipment service information see chassis shop manual.
Mounting Adaptations - Group 16
Mounting Adaptations - Group 16

Section Contents
Page
Engine Support Bracket, Front - Cleaning and Inspection for Reuse . . . . . . . . . . . . . . . . . . . . . . . 16-9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9
lnspection............................................................... 16-9
Flexplate Assembly - Cleaning and Inspection for Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Flywheel - Cleaning and Inspection for Reuse ...................................... 166

Cleaning.. .............................................................. 16-5
Inspection ............................................................... 16-5
Flywheel Housing - Assembly (Wet Clutch Application) ................................ 16-8
Flywheel Housing - Cleaning and Inspection for Reuse ................................ 16-7

Cleaning.. .............................................................. 16-7
Inspection ............................................................... 16-7
Flywheel Ring Gear - Replacement .............................................. 16-6

Installation .............................................................. 16-6
Removal ................................................................ 16-6
Mounting Adaptations - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Mounting Adaptations - General Information ........................................ 164

Flywheel and Ring Gear ..................................................... 16-4
Flywheel Housing .......................................................... 16-4
Mounting Adaptations - Service Tools ............................................ 16-2

Mounting Adaptations - Service Tools Mounting Adaptations - Group 16
Mounting Adaptations - Service Tools

Crack Detection Kit
This kit provides a convenient way to detect cracks in any

3375432 engine component.
Mounting Adaptations - Group 16 Mounting Adaptations - Exploded View
Mounting Adaptations - Exploded View

1 Screw, Hexagon Head Cap 12 11 Gear, Flvwheel Ring 1
2 Plug, Threaded 12 Screw, Hexagon Head Cap
3 Housing, Flywheel 13 Washer, Plain
4 Plug, Pipe 14 Adapter, Crankshaft
5 Gasket, Cover Plate 15 Flexplate
6 Plate, Cover 16 Ring, Clamping
7 Screw, Self Tapping Metal 17 Screw, Hexagon Head Cap
8 Seal, O-ring 18 Support, Engine, Front
9 Plug, O-ring 19 Screw, Hexagon Head Cap
10 Flywheel
Mounting Adaptations - General Information Mounting Adaptations - Group 16
Mounting Adaptations - General Information

The mounting adaptations group consists of the flywheel housing, flywheel, flywheel ring gear, pilot bearing, and the front
engine support.
Flywheel Housing
The flywheel housings are available in different sizes and styles for the various applications. Ring dowels are used to
locate the housing within 0.20 mm [0.008 in] total indicated runout. Service housings are drilled for the dowels and
redowelling is not required. Check the appropriate parts book and the engine parts listing for the correct part number
for the engine application being serviced.
Flywheel and Ring Gear
The flywheel is available only as an assembly. The assembly includes the flywheel and the ring gear. The ring gear is
available for service replacement.
Mounting Adaptations - Group 16 Flywheel - Cleaning and Inspection for Reuse (16-01)
Flywheel - Cleaning and Inspection for

Reuse (16-01)
Cleaning
Use a wire brush to clean the crankshaft pilot bore.
A
B
Use steam or solvent to clean the flywheel. Dry with •1
compressed air.
Inspection
Visually inspect for nicks or burrs.
Use Scotch-BriteQ 7446, or equivalent, to remove small nicks 0a3
q
and burrs.
\
Crack Detection. Kit, Part No. 3375432

Warning: Komatsu Dresser Company does not •l
A
recommend resurfacing of the flywheel. Resurfacing of
the flywheel can cause possible personal injury, property
damage, or cause the flywheel to be too thin and result
0al9
in breakage.
Check the face of the flywheel at the clutch engagement
point for cracks or damage.
Use the crack detection kii, Part No. 3375432, to check for e
cracks in the flywheel. Follow the instructions provided with
the kit.
0ai!3
Inspect the flywheel ring gear teeth for cracks and chips.
NOTE: If the ring gear teeth are cracked or broken, the ring
gear must be replaced. Refer to Procedure (16-03).
Flexplate Assembly - Cleaning and Inspection for Reuse (16-02) Mounting Adaptations - Group 16
Page 16-6 614 Skies
Flexplate Assembly - Cleaning and

Use solvent to clean the flexplate.
Check the ring gear for damaged or worn teeth. If the ring gear
is damaged or worn, it must be replaced. Refer to Procedure,
Flywheel Ring Gear - Replacement (16-03).
Use dye penetrant to check the crankshaft adapter for cracks.

There must not be any cracks in the crankshaft adapter.
Check the pilot on the crankshaft adapter for damage or wear.
If the pilot is worn, the flexplate must be replaced.
fwSadsa
Flywheel Ring Gear - Replacement

(16-03)
Removal
Caution: Do not use a cutting torch to heat the ring gear,
the flywheel can be damaged.
Heat the outside diameter of the ring gear with a heating torch.
Warning: Wear eye protection while driving the gear from
the flywheel.
Use a blunt chisel or brass drift and hammer to remove the
gear from the flywheel.
Installation
NOTE: Do not attempt to install the ring gear without heating
the ring gear first.
Use an oven to heat the new ring gear. Heat the ring gear for
a minimum of 30 minutes in a preheated oven. Do not heat the
ring gear for more than 6 hours.
Temperature: 177°C [350” F]
NOTE: Do not exceed the specified time or temperature. The
metal hardness will be changed.
Mounting Adaptations - Group 16 Flywheel Housing - Cleaning and Inspection for Reuse (1604)
614 Series Page 167
Caution: Wear protective gloves to prevent personal injury

when handling parts that have been heated.
NOTE: The gear must be installed so the bevel on the teeth
A
is toward the crankshaft side of the flywheel.
Remove the gear from the oven, and install it on the flywheel
before it cools. Allow the air to cool the gear. Do not use
water or oil to reduce the cooling time.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 177°C @
[35O”F]. Use a Tempilstip crayon or its equivalent to check @
the gear temperature before installing it on the flywheel.
Flywheel Housing - Cleaning and

Cleaning
A
Use steam or solvent to clean the flywheel housing. Dry with
compressed air. q
\
Inspection
Visually inspect all surfaces for nicks, burrs, or cracks.
Use Scotch Briie@ 7446, or equivalent, to remove small nicks
and burrs.
0629
0a3
Inspect all threaded capscrew holes for damage.
Repair or replace the housing if the capscrew holes are
damaged.
fh9OOsb
Flywheel Housing - Assembly (Wet Clutch Application) (16-05) Mounting Adaptations - Group 16
Page 16-6 614 Skies
Flywheel Housing - Assembly (Wet

Clutch Application) (16-05)
Coat the flywheel housing drain plug with pipe sealant and
install into the hole in the bottom of the flywheel housing.
Tighten the plug.
Refer to the pipe plug torque values in Group 18 for different
plug sizes.
Install the plastic plug into the tachometer drive access hole.
fh9pxha
13 mm
Install the access plate and new gasket.
Install the capscrews and tighten.
Install the plug into the barring gear hole.
fhsplha
NOTE: The capscrew holes on the center mounting pads are

drilled through. Coat the set screws with Loctitem 277 and
install into holes.
Set Screw Installation Depth

mm in
0.00 MIN 0.000
3.00 MAX 0.118
fhspxhc
Mounting Adaptations - Group 16 Engine Support Bracket, Front - Cleaning and inspection for Reuse (16-06)
Engine Support Bracket, Front - Cleaning

and Inspection for Reuse (16-06)
A
Cleaning
Steam clean or use solvent, and dry with compressed air.
Inspection
qB
Visually inspect the engine support bracket for cracks or

damage. If cracks or damage are found, the support bracket
must be replaced.
0
@
Specifications and Torque Values - Group 18
614 Series Page V-l
Section V - Specifications and Torque Values - Group 18

Section Contents
Page
Air Compressor Inspection Specifications ......................................... V-37
Air Compressor Torque Values ................................................. V-37
Capscrew Markings and Torque Values ........................................... V-45

Capscrew Markings and Torque Values - Metric ..................................... Va
Capscrew Markings and Torque Values - U.S. Customary ............................... V-48
Component Specifications and Torque Values ...................................... V-3

Cylinder Block - Rebuild Specifications ........................................... V-15
Cylinder Block - Torque Values ................................................ V-21
Cylinder Head - Rebuild Specifications ........................................... V-22
Engine Assembly - Specifications ............................................... V-3
Engine Assembly - Torque Values ............................................... V-5
Cooling System Specifications ................................................. V-33

Air Intake System Specifications ................................................ V-35
Air Intake System Torque Values ............................................... V-35
Cooling System Torque Values ................................................. V-34
Drive Belt Tension .......................................................... V-41
Electrical System Specifications ................................................ V-38
Electrical System Torque Values ................................................ V-38
Engine Components - General Information ......................................... V-2
Engine Testing - Test Specifications ............................................. V-39
Exhaust System Specifications ................................................. V-37
Exhaust System Torque Values ................................................. V-37
Fuel Systems - Rebuild Specifications ............................................ V-25

Fuel Injection Pump Sealing Washer ............................................. V-27
Fuel Shutoff Solenoid Adjustment ............................................... V-27
Fuel System Specifications ................................................... V-25
Fuel System Torque Values ................................................... V-27
Lubricating Oil System Specifications ............................................ V-30
Lubricating Oil System Torque Values ............................................ V-31
Mounting Adaptations - Torque Values ........................................... V-48
Mounting Adaptations Specifications ............................................. V-39

Flywheel Housing (Wet Application) ............................................. V-39
Flywheel Ring Gear Installation ................................................. V-40
Newton-Meter to Foot-Pound Conversion Chart ..................................... V-44
Pipe Plug Torque Values ..................................................... V-47
Rocker Lever Assembly - Rebuild Specifications ..................................... V-25
Tap-Drill Chart - U.S. Customary & Metric ......................................... V-48
Valve Tappet - Rebuild Specifications ............................................ V-25
Weight and Measures - Conversion Factors ........................................ V-43

Engine Components - General Information Specifications and Torque Values - Group 18
Page V-2 614 Series
Engine Components - General Information

The specifications in this section are organized in the same sequence used in each group of this manual. The minimum
and maximum tolerance limit specifications are listed in both metric and U.S. Customary dimensions. The metric dimension
is given first, followed by the U.S. Customary dimension in brackets; for example: 0.50 mm [0.020 inch]. The assembly
and rebuild specifications and torque values are provided to be sure the parts are assembly correctly, fit property, and
are secured with correct torque value.
Most of the capscrews used to assembly the 614 Series engine are metric. Some components, such as the air
compressor and hydraulic pump, are installed using U.S. Customary capscrews. Capscrew torque value are listed in
newton-meters and foot pounds, unless otherwise specified. If a torque value is not listed, use the standard torque value
for the capscrew, refer to the Capscrew Markings and Torque Values, on page V-46.
Specifications and Torque Values - Group 18 Component Specifications and Torque Values
814 Series Page V-3
Component or Assembly (Procedure) Ref.No./Steps Metric U.S.
Component Specifications and Torque Values

Engine Assembly - Specifications
Cylinder Liner Protrusion 0.025 mm MIN 0.001 in
0.122 mm MAX 0.0048 in
Note: Use Part No. 3822503, Cylinder Liner Clamp
Set to seat the liner into the bore. Check the liner
protrusion with the clamps removed.
Cylinder Liner-to-Block Clearance 0.229 mm MIN 0.009 in
Cylinder Liner Out-of-Round 0.04 mm MAX 0.0016 in
Cylinder Blqck Upper Liner Bore I.D. 132.900 mm MIN 5.2323 in

132.990 mm MAX 5.2358 in
Cylinder Liner Top Press Fit O.D. 132.938 mm MIN 5.2338 in

132.958 mm MAX 5.2346 in
Crankshaft End Clearance

New 0.157 mm MIN 0.0062 in
0.334 mm MAX 0.0131 in
Used 0.535 mm MAX 0.0210 in
Piston Ring Gap (New)

Top Ring Gap 0.40 mm MIN 0.0157 in
0.70 mm MAX 0.0275 in
lnteimediate Ring Gap 0.40 mm MIN 0.0157 in
0.70 mm MAX 0.0275 in
Oil Control Ring Gap 0.30 mm MIN 0.0118 in
0.60 mm MAX 0.0236 in
Component Specifications and Torque Values Specifications and Torque Values - Group 18
Page V-4 614 Series
Connecting Rod Bearing Side Clearance 0.100 mm MIN 0.0039

0.330 mm MAX 0.0130
Oil Pump Drive Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in
Oil Pump Idler Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in
Camshaft Gear Backlash 0.152 mm MIN 0.006 in

0.380 mm MAX 0.015 in
Camshaft End Clearance 0.12 mm MIN 0.0047 in

0.46 mm MAX 0.0181 in
Flywheel Bore Runout T.I.R. 0.127 mm MAX 0.0050 in
Flywheel Face Runout T.I.R. Radius (A)

mm in
203 8 0.203 mm MAX 0.008 in
254 10 0,254 mm MAX 0.010 in
305 12 0.305 mm MAX 0.012 in
356 14 0.356 mm KG 0.014 in
406 16 0.406 mm 0.016 in
Valve Adjustment Clearance

Intake Valve 0.30 mm Nominal 0.012 in
Exhaust Valve 0.61 mm Nominal 0.024 in
614 Series Page V-5
Vibration Damper Face Alignment

(Wobble) T.I.R. 0.28 mm MAX 0.011 in
Vibration Damper Eccentricity T.I.R. 0.28 mm MAX 0.011 in
Engine Assembly - Torque Values

Cylinder Liner Clamps 68 Narn 50 ft-lb
Main Bearing Cap Capscrews Step 1 50 N*m 37 ft-lb

119 N*m 88 ft-lb
32 176 N*m 129 ft-lb
Connecting Rod Nuts Step 1 40 Nom 30 ft-lb

80 Nom 60 ft-lb
: 120 Nom 88 ft-lb
p8ar Housing Mounting Capscrews

24 Nom 18 ft-lb
Ml2 60 N*m 44 ft-lb
Oil Pump Mounting Capscrews 24 Nom 18 ft-lb

Page V-8 814 Series
Water Pump Mounting Capscrews 24 N*m 18 ft-lb
Oil Pump Suction Tube to Block A 9 Nom 80 in-lb

Brace to Block 9 Nom 80 in-lb
Brace to Suction Tube : 9 N*m 80 in-lb
Oil Pan Mounting Capscrews 24 Nom 18 ft-lb

Note: Tighten the capscrews in the sequence
shown. Start at the center of the oil pan and
alternate toward both ends.
Oil Pan Drain Plug 80 Nom 59 ft-lb
Timing Pin Torx’” Capscrews 8 Nom 71 in-lb
Flywheel Housing Mounting Capscrews 60 Nom 44 ft-lb
Flywheel Housing Access Plate

Capscrews 24 Nom 18 ft-lb
614 Series Page V-7
Flywheel Mounting Capscrews 140 N*m 101 ft-lb
Starting Motor Mounting Capscrews 77 N*m 57 ft-lb
Coolant Heater 12 N*m 106 in-lb
Oil Cooler Mounting Capscrews 24 Nom 18 ft-lb

Oil Filter Head Mounting Capscrews 24 Nom 18 ft-lb
Cylinder Head Mounting Capscrews Step 1 70 N*m (All Capscrews) 52 ft-lb

2 145 N*m (Long Only) 105 ft-lb
3 Rotate 90 Degrees (All Capscrews)
shown. Start at the center of the cylinder head
and alternate toward both ends.
Rocker Lever Retaining Clamp Capscrews 55 N*m 41 ft-lb
Rocker Lever Adjusting Screw Locknut 24 N*m 18 ft-lb

Page V-8 814 Series
Valve Cover Capscrews 24 N*m 18 ft-lb

shown. Start at the center of the valve cover
and alternate toward both ends.
Crankcase Breather Tube

Support Bracket Capscrews A 24 Nom 18 ft-lb
B 43 Nom 32 ft-lb
Injection Nozzle Clamp Capscrew 24 Nom 18 ft-lb
Fuel Drain Manifold

Banjo Connector
l Injector 9 N*m 80 in-lb
l Filter Head 15 N*m 11 ft-lb
Engine Lifting Bracket Capscrews 77 N*m 57 ft-lb
Intake Manifold Cover Capscrews 24 Nom 18 ft-lb
Aftercooler Assembly Capscrews 24 Nom 18 ft-lb

814 Series Page V-9
Aftercooler Coolant Supply Tube

Capscrews 6 Narn 53 in-lb
Exhaust Manifold Mounting Capscrews 43 N*m 32 ft-lb
Turbocharger Mounting Studs 10 N*m 89 in-lb
Turbocharger Mounting Nut 45 Nom 33 f&lb
Turbocharger Oil Drain Mounting

Capscrew 24 N*m 18 ft-lb
Turbocharger Oil Drain Line Hose Clamps 5 N*m 44 in-lb
Turbocharger Turbine Housing Capscrews 20 N*m 15 ft-lb

Page V-10 814 Series
Turbocharger Compressor Housing Clamp

V-Band Clamp Nut 8 Nom 71 in-lb
Actuator Bracket Brace Capscrews 13 Nom 115 in-lb
Turbocharger Oil Supply Hose

Fittings 24 Nom 18 ft-lb
Hose Connection 35 Nom 26 ft-lb
Turbocharger Exhaust Outlet:

Band Clamp 8 Nom 71 in-lb
Capscrews 43 Nom 32 ft-lb
Turbocharger Air Crossover Hose Clamps 5 N*m 44 in-lb
Water Outlet Connection Capscrews 24 Nom 18 ft-lb
Coolant Vent Line Fitting 8 N*m 71 in-lb
Coolant Vent Petcock 5 N*m 44 in-lb

814 Series Page V-l 1
Coolant Vent Line Tube 8 Nom 71 in-lb
Coolant Inlet Connection Hose Clamps 5 N*m 44 in-lb
Alternator Mounting Bracket Capscrews 24. Nom 18 ft-lb
Water Pump Mounting Capscrew 24 Nom 18 ft-lb
Alternator Mounting Capscrew 43 Nom 32 ft-lb

24 Nom 18 ft-lb
80 Nom 59 ft-lb
Belt Tensioner Mounting Bracket 24 N*m 18 ft-lb
Belt Tensioner Mounting Capscrews 43 Nom 32 ft-lb

Fan Hub Mounting Capscrews 24 Nom 18 ft-lb
Fuel Injection Pump

Mounting Nuts 44 Nom 32 ft-lb
Studs Hand Tight
Fuel Injection Pump Timing Pin Access

Plug 40 Nom 30 ft-lb
Fuel Injection Pump Drive Gear Nut

A Pump 92 Nom 68 ft-lb
MW Pump 104 Nom 77 ft-lb
P Pump 165 N*m 122 ft-lb
Fuel Injection Pump Supply Banjo Fitting 24 N*m 18 ft-lb
Fuel Filter Head Adapter 4 N*m 35 in-lb

Fuel Filter Adapter Nut 32 N*m 24 ft-lb
Fuel Filter
614 Series Page V-13
High Pressure Fuel Line Fittings 30 Nom 22 ft-lb
High Pressure Fuel Line Support Bracket 24 Nom 18 ft-lb
Gear Cover Capscrews 24 N*m 18 ft-lb
Vibration Damper 200 Nmrn 148 ft-lb

Pulley to Vibration Damper 77 Nom 57 ft-lb
Fan Hub Pulley Mounting Capscrews 45 Nom 32 ft-lb
Front Engine Support Bracket Mounting

Capscrews 112 N*m 83 ft-lb
l Without Support 60 N*m 44 ft-lb
Fuel Transfer Pump Mounting Capscrews 24 Nom 18 ft-lb

Page V-l 4 614 Series
Fuel Transfer Pump Fuel Line Fittings 24 Nam 18 ft-lb
Fuel Injection Pump Solenoid 10 Nom 89 in-lb
Air Compressor Mounting Nuts 77 N*m 57 ft-lb
Air Compressor Support Brace Capscrews 43 Nom 32 ft-lb
Air Compressor Oil Supply Line Fitting 8 Nom 71 in-lb
Air Compressor Coolant Supply Line

Fitting 35 Nom 26 in-lb
Air Compressor Connections

Inlet 5 N*m 48 in-lb
Outlet 24 N*m 18 ft-lb
Cylinder Block - Rebuild Specifications

Cylinder Block Head Deck Flatness
End-to-End 0.075 mm MAX 0.0030 in
Side-to-Side 0.075 mm MAX 0.0030 in
Cylinder Block Upper Liner Bore I.D. 132.900 mm MIN 5.2323 in

132.990 mm MAX 5.2358 in
Cylinder Block Counterbore Depth From

Cylinder Block Head Deck 122.930 mm MIN 4.8397 in
123.000 mm MAX 4.8425 in
Cylinder Block Height From Head Deck

Surface to Top of Main Bearing Bore 309.40 mm MIN 12.181 in
309.60 mm MAX 12.189 in
Cylinder Block Height From Head Deck

“,wfxe to Centerline of the Main Bearing
361.90 mm MIN 14.248 in
362.10 mm MAX 14.256 in
Main Bearing Bore Diameter

With New Bearings 98.079 mm MIN 3.8614 in
98.125 mm MAX 3.8632 in
Without Bearings 104.982 mm MIN 4.1331 in

105.018 mm MAX 4.1346 in
Camshaft Bore Diameter

Without Bushing 64.01 mm MAX 2.520 in
With Bushing lnsialled 60.12 mm MAX 2.367 in

Valve Tappet Bore Diameter 16.00 mm MIN 0.630 in

16.05 mm MAX 0.632 in
Cylinder Liner Inside Diameter 114.000 mm MIN 4.4882 in

114.117 mm MAX 4.4928 in
Cylinder Liner Out-of-Round 0.04 mm MAX 0.0016 in
Cylinder Liner Taper 0.04 mm MAX 0.0016 in
Cylinder Liner Seat Area Depth 123.013 mm MIN 4.8430 in

123.039 mm MAX 4.8440 in
Cylinder Liner O.D. (Top Press Fit) 132.938 mm MIN 5.2338 in

132.958 mm MAX 5.2346 in
Piston Pin Bore Inside Diameter 45.006 mm MIN 1.7719 in

45.025 mm MAX 1.7726 in
Piston Pin Outside Diameter 44.993 mm MIN 1.7714 in

45.003 mm MAX 1.7718 in
Note: Discard the piston pin if it is more than
0.03 mm [O.OOl inch] out of round.
Piston Skirt Outside Diameter 113.814 mm MIN 4.4810 in

113.886 mm MAX 4.4840 in
Top Ring Groove Keystone Angle Wear

Use micrometer and Part No. 3823966. 113.938 mm MIN 4.4857 in
Intermediate Ring Groove Keystone Angle

Wear
Use micrometer and Part No. 3823965. 114.323 mm MIN 4.5009 in
Intermediate Rectangular Ring Side

Clearance 0.070 mm MIN 0.0028 in
0.150 mm MAX 0.0059 in
Oil Control Ring Side Clearance 0.020 mm MIN 0.0008 in

0.130 mm MAX 0.0051 in
Crankshaft Oil Seal Wear Groove, Front

and Rear 0.025 mm MAX 0.010 in
Crankshaft Connecting Rod Journal

l Outside Diameter 75.962 mm MIN 2.9906 in
76.013 mm MAX 2.9926 in
l Out-of-Round 0.050 mm 0.0020 in

l Taper 0.013 mm MAX 0.0005 in
Crankshaft Main Bearing Journal

l Outside Diameter 97.962 mm MIN 3.8568 in
98.031 mm MAX 3.8595 in
l Out-of-Round 0.050 mm MAX 0.0020 in

l Taper 0.013 mm MAX 0.0005 in
Crankshaft Thrust Face Width (Standard) 42.975 mm MIN 1.6919 in

43.076 mm MAX 1.6959 in
Crankshaft Rear Oil Seal Flange O.D. 129.975 mm MIN 5.1171 in

130.025 mm MAX 5.1191 in
Crankshaft Damper Pilot O.D. 23.924 mm MIN 0.9419 in

24.000 mm MAX 0.9449 in
Crankshaft Gear Journal O.D. 75.987 in MIN 2.991 in

76.006 mm MAX 2.992 in

New 0.157 mm MIN 0.0062 in
0.334 mm MAX 0.0131 in
Used 0.535 mm MAX 0.0210 in
ks2COjah
Crankshaft Gear Bore I.D. 75.898 mm MIN 2.9881 in

75.923 mm MAX 2.9891 in
Crankshaft Gear Installation

- Austempered Gear: 149% MAX 300°F
l Temperature 45 Min. MIN 45 Min.
l Time 6 Hrs. MAX 6 Hrs.
- Steel Gear: 177% MAX 350°F

l Time 6 Hrs. MAX 6 Hrs.
Standard Main Bearing Thickness (Used) 3.446 mm MIN 0.1357 in

3.454 mm MAX 0.1360 in
Main Bearing Clearance With Plastigauge 0.066 mm MIN 0.0026 in

0.134 mm MAX 0.0053 in
Thrust Bearing Flange Thickness 3.417 mm MIN 0.1345 in

3.530 mm MAX 0.1389 in
Connecting Rod Piston Pin I.D.

With Bushing 45.023 mm MIN 1.7726 in
45.060 mm MAX 1.7740 in
Without Bushing 48.988 mm MIN 1.9286 in

49.012 mm MAX 1.9296 in
Connecting Rod Crankshaft Bore I.D.

(With Bearings) 76.046 mm MIN 2.9939 in
76.104 mm MAX 2.9962 in
Connecting Rod Bearing Clearance (With

Plastiguage) 0.033 mm MIN 0.0013 in
0.117 mm MAX 0.0046 in
Connecting Rod Bearing Side Clearance 0.100 mm MIN 0.0039

0.330 mm MAX 0.0130
Connecting Rod Bearing Thickness

(Standard) 2.428 mm MIN 0.0956 in
2.471 mm PAX 0.0973 in
Connecting Rod Length 215.975 mm MIN 8.5029 in

216.025 mm MAX 8.5049 in
Connecting Rod Bend (Alignment)

l Without Bushing 0.20 mm MAX 0.008 in
l With Bushing 0.15 mm MAX 0.006 in

Connecting Rod Twist

l Without Bushing 0.50 mm MAX 0.020 in
l With Bushing 0.30 mm MAX 0.012 in
Camshaft Bore Diameter

l With Bushing 60.12 mm 2.367 in
l Without Bushing 64.01 mm 2.520 in

Note: If one of the bushings exceeds the
specifications, all of the bushingsmust be
replaced.
Camshaft Journal Outside Diameter 59.962 mm MIN 2.3607 in

60.013 mm MAX 2.3627 in
Camshaft Lobe Diameter

Intake Lobe 51.774 mm MIN 2.0383 in
(?:,0
A
Exhaust Lobe
Fuel Transfer Pump Lobe

52.251
51.596
52.073
41.310
41.829
mm
mm
mm
mm
mm
MAX
MIN
MAX
MIN
MAX
2.0571
2.0313
2.0501
1.6264
1.6468
in
in
in
in
in
Camshaft Nose (Gear Mounting Surface)

Outside Diameter 41.562 mm MIN 1.6363 in
41.580 mm MAX 1.6370 in
Camshaft Thrust Plate Thickness 9.340 mm MIN 0.3677 in

0 9.580 mm MAX 0.3772 in
H 0
4 k-- -...
Camshaft Gear Bore Inside Diameter 41.480 mm MIN 1.6331 in

41.505 mm MAX 1.6341 in
Camshaft Gear Installation

- Austempered Gear: 149v MAX 3OO=‘F
l Heating Time 6 Hrs. MAX 6 Hrs.
- Steel Gear: 177% MAX 35O=‘F

l Heating Time 6 Hrs. MAX 6 Hrs.
Vibration Damper Face Alignment

(Wobble ) T.I.R. 0.28 mm MAX 0.011 in
Vibration Damper Eccentricity T.I.R. 0.28 mm MAX 0.011 in
Vibration Damper Thickness

Measure the thickness at four locations 90 degrees apart approximately 3.18 mm [0.125 in] from
the outside diameter. The difference between any two of the four measurements must not exceed
0.25 mm [O.OlO in].
Rear Cover Crankshaft Seal Bore I.D. 149.96 mm MIN 5.904 in

150.04 mm MAX 5.907 in
Cylinder Block - Torque Values

Cylinder Block Pipe Plugs (Into Cast Iron) Size
Refer to chart on page V-47. 10 Nam l/l6 inch 7 ft-lb
15 Nom l/8 inch 11 ft-lb
25 N*m l/4 inch 20 ft-lb
35 Nom 318 inch 25 ft-lb
55 N@m l/2 inch 40 ft-lb
75 N*m ;14$hch 55 ft-lb
95 N*m 70 ft-lb
Cylinder Block - Main Bearing Cap

Capscrew 1 50 N*m 37 ft-lb
119 Nom 88 ft-lb
: 176 N*m 129 ft-lb
Connecting Rod Capscrew Nuts : 40 Nom 30 ft-lb

80 N*m 60 h-lb
3 120 N*m 88 ft-lb
Cylinder Head - Rebuild Specifications

fy;;t;er Head Capscrew Free Length
81.5 mm MAX 3.21 in
l Long 162.6 mm MAX 6.40 in
Cylinder Head Flatness

End-to-End 0.200 mm MAX 0.0079 in
Side-to-Side 0.076 mm MAX 0.0030 in
Local Flatness
(Within a 51 mm 12.0 inch] area) 0.0254 mm MAX 0.001 in
Cylinder Head Thickness

l New 115.75 mm MIN 4.557 in
116.25 mm MAX 4.577 in
l Machined 114.75 mm MIN 4.518 in
Injector Nozzle Tip Protrusion 3.0 mm MIN 0.118 in

4.0 mm MAX 0.157 in
Valve Guide I.D. (Installed)

l New 9.539 mm MIN 0.3756 in
9.559 mm MAX 0.3763 in
. Used 9.591 mm MAX 0.3776 in
;Fk: Guide Height (Installed)

20.65 mm MIN 0.813 in
21.16 mm MAX 0.833 in
Exhaust 22.50 mm MIN 0.886 in

23.01 mm MAX 0.906 in
Valve Guide Bore I.D. 15.931 mm MIN 0.6272 in

15.971 mm MAX 0.6288 in
Valve Guide (New) O.D. 15.988 mm MIN 0.6294 in

16.000 mm MAX 0.6299 in
Valve Seat-to-Valve Guide Concentricity

(360 Degrees) 0.05 mm MAX 0.002 in
Valve Recess in Cylinder Head 1.09 mm MIN 0.043 in

1.62 mm MAX 0.064 in
z;lv; Insert Bore I.D. (Standard Insert) A

53.930 mm MAX 2.1231 in
Exhaust 47.027 mm MAX 1.8515 in
$:I$ Insert Bore Depth (Standard Insert) B

12.20 mm MAX 0.480 in
Exhaust 9.83 mm MAX 0.387 in
Valve Sealing Surface Angle

Intake 3o”
Exhaust 45O
Valve Seat Width Limit 1.5 mm MIN 0.060 in

2.0 mm MAX 0.080 in
Valve Seat Vacuum

New 508 mm Hg MIN 20 in Hg
635 mm Hg MAX 25 in Hg
Used 457 mm Hg MIN 18 in Hg

Acceptable leakage rate in 10 seconds. 254 mm Hg MAX 10 in Hg
Valve Spring Free Height A 65.66 mm Nominal 2.585 in

(7-112 coils)
Valve Spring Working Height B 50.80 mm Nominal 2.00 in

SNprxg Force at Assembled Height
C 464.5 N MIN 104.4 Ibf
513.5 N MAX 115.4 Ibf
Used C 450.0 N MIN 101.2 Ibf
Valve Spring at Opening Height 37.90 mm Nominal 1.492 in

Spring Force at Opening Height
New 959.5 N MIN 215.7 Ibf
1060.5 N MAX 238.4 Ibf
Used 940.0 N MIN 211.3 Ibf
Valve Stem O.D. 9.46 mm MIN 0.372 in

9.50 mm MAX 0.374 in
Valve Head Thickness at O.D. 1.50 mm MIN 0.059 in

Specifications and Torque Values - Group 18 Rocker Lever Assembly - Rebuild Specifications
Rocker Lever Assembly - Rebuild Specifications

Rocker Lever Bore I.D. 22.256 mm MIN 0.8762 in
22.301 mm MAX 0.8780 in
Rocker Lever Shaft O.D. 22.199 mm MIN 0.8740 in

22.231 mm MAX 0.8752 in
Valve Tappet - Rebuild Specifications

Valve Tappet Stem O.D. 15.925 mm MIN 0.6270 in
15.980 mm MAX 0.6291 in
Valve Tappet Visual Limits

Inspect the socket stem and face (4 Normal Wear
for excessive wear, cracks or damage (B) Abnormal (Do not use)
(C) Abnormal (Do not use)
Concavity (A) 0.025 mm 0.001 in
Valve Tappet Face

1. A single pit cannot be greater than 2 mm [0.078 in] in diameter.
2. Interconnection of pits is not allowed and is treated as one pit.
3. Total pits when added together should not exceed 6 mm [0.236 in]
diameter or a total of 4 percent of the tappet face.
4. No pitting is allowed on the edges of the wear face of the valve tappet.
Fuel Systems - Rebuild Specifications

Note: This manual does not cover fuel injection pump rebuild or calibration.
Rebuild and calibration should be per-formed in a facility certified in the
rebuild and calibration of the fuel injection pumps.
Refer to Bulletin No. 3810348 for additional service and parts information.
Fuel System Specifications

Engine Low Idle Speed
Refer to the engine dataplate.
Fuel Rebuild - System Specifications Specifications and Torque Values - Group 18
Fuel Transfer Pump Inlet Restriction

6C, 6CT 95 mm Hg MAX 3.75 in Hg
6CTA 153 mm Hg MAX 6 in Hg
Fuel Transfer Pump Outlet Pressure at

High Idle
6C, 6CT 172 kPa MAX 25 psi
6CTA 207 kPa MAX 30 psi
Fuel Injection Pump

Fuel Inlet Pressure 140 kPa MIN 20 psi
Fuel Injection Pump

Fuel Return Line Restriction 518 mm Hg MAX 20.4 in Hg
Fuel Filter Restriction

Pressure Drop Across Filter 35 kPa MAX 5 psi
Fuel Drain Line Restriction 70 kPa MAX 10 psi
Fuel Injection Pump Throttle Lever

Breakover 3.18 mm MIN 0.125 in
6.35 mm MAX 0.250 in
Specifications and Torque Values - Group 18 Fuel Rebuild - System Specifications
Fuel Shutoff Solenoid Adjustment

- Synchro-Start
l Plunger Stroke Gap 0.04 mm MAX 0.118 in
l Plunger Stroke Length 25.4 mm MAX 1 .O in
- Trombetta
l Plunger Stroke Gap 0.04 mm MAX 0.118 in
l Plunger Stroke Length 33.3 mm MAX 1.3 in
Fuel Shutoff Solenoid Adjustment

RQVK Governor A 66.9 mm 2.64 in
Fuel System Torque Values

Air Fuel Control (AFC) Fitting 24 Nom 18 ft-lb
Fuel Filter
Fuel Injection Pump Sealing Washer

- Bosch Pump
l Sealing Washer A 24 Nom 18 ft-lb
l Sealing Washer D 15 Nom 11 ft-lb
Fuel Injection Pump Sealing Washer

- Nippondenso Pump
l Sealing Washer A 24 N*m 18 ft-lb
l Sealing Washer 14 Nom 10 ft-lb
l Sealing Washer : 27 Nom 20 ft-lb
l Sealing Washer D 70 Nom 50 ft-lb
l Sealing Washer (Bleed Screw) E 5 N*m 36 in-lb
Fuel Filter Head Adapter 4 Nom 35 in-lb

Fuel Filter Adapter Nut 32 Nom 24 ft-lb
Fuel Rebuild - System Specifications Specifications and Torque Values -‘Group 18
Fuel Filter Head Banjo Fittings 24 Nom 18 ft-lb
Fuel Injection Pump Solenoid Mounting

Capscrews 43 N*m 32 fi-lb
Fuel Injection Pump Supply Banjo Fitting 24 N*m 18 ft-lb
Fuel Injection Pump

Mounting Nuts 44 N*m 32 ft-lb
Studs Hand Tight
Fuel Injection Pump Lower Support

Bracket
Ml0 Pump to Support Bracket Capscrew 24 Nom 18 ft-lb
Ml0 Support Bracket to Block Capscrew 77 Nom 57 ft-lb
Fuel Injection Pump Drive Gear .Nut

A Pump 92 N*m 68 ft-lb
MW Pump 104 N*m 77 ft-lb
P Pump 165 N*m 122 ft-lb
Fuel Injection Pump Timing Pin Access

Plug 15 N*m 11 ft-lb
Specifications and Torque Values - Group 18 Fuel Rebuild - System Specifications
Fuel Shutoff Solenoid Mounting Bracket

Capscrews 10 Nom 89 in-lb
Fuel Transfer Pump Fittings

- Outlet 30 N*m 22 ft-lb
- Inlet 30 N*m 22 ft-lb
- Hand Primer 30 N*m 22 ft-lb
Fuel Transfer Pump 24 Nmrn 18 ft-lb

Fuel Line Fittings
Fuel Transfer Pump Mounting Capscrews 24 Nom 18 ft-lb
High Pressure Fuel Line Fittings 30 N*m 22 ft-lb
High Pressure Fuel Line Support Bracket 24 N*m 18 ft-lb
Injector Opening Pressure

a. Open valve
b. Operate spray tester lever at one stroke per second
c. Read pressure indicated when spray began
Lubricating Oil System Specifications Specifications and Torque Values - Group 18
Leakage Test:
a. Open valve
b. Operate spray tester lever to hold pressure 20 bar (290 psi] below opening pressure
c. No drops should fall from the tip within 20 seconds
Injector Nozzle Clamp Capscrew 24 N*m 18 ft-lb
Injector Nozzle Banjo Fitting 9 Nom 80 in-lb
Lubricating Oil System Specifications

Lubricating Oil Thermostat
l Fully Open Temperature 116% MAX 24O“F
l Maximum Opening Distance 45.9 mm MAX 1.80 ‘in
Oil Capacity of Pan (All Engines):

- Low Level 15.1 liters 16.0 U.S. Qts.
- High Level 18.9 liters 20.0 U.S. Qts.
To;G&8T!stem Capacity
23.6 liters 25.0 U.S. Qts.
6CT8.3 23.8 liters 25.2 U.S. Qts.
Oil Cooler Distortion 0.8 mm MAX 0.031 in
Oil Cooler Element Pressure Test

Pressure 483 kPa 70 psi
Temperature 82% 18OOF
Specifications and Torque Values - Group 18 Lubricating Oil System Specifications
Oil Pressure Regulator Spring

Spring Free Length
13-coils 86.63 mm Nominal 3.411 in
Spring Load at 53.98 mm [2.125 in]

Valve Open
Spring Load at 60.33 mm 12.375 in]
190 N MIN 42.8 Ibf __L
Assembled 153 N MIN 34.4 Ibf
-
Oil Pump Gerotor Tip Clearance 0.025 mm MIN 0.001 in
0.178 mm MAX 0.007 in
Oil Pump Port Plate Clearance 0.025 mm MIN 0.001 in

0.127 mm MAX 0.005 in
Oil Pump Body Bore Clearance 0.127 mm MIN 0.005 in

0.381 mm MAX 0.015 in
Oil Pump Drive Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in
Oil Pump Idler Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in
Lubricating Oil System Torque Values

Crankcase Breather Tube Bracket
M8 (Valve Cover) 24 Nom 18 ft-lb
Ml2 (Cylinder Head) 80 Nom 59 ft-lb
Lubricating Oil System Specifications Specifications and Torque Values - Group 18
Oil Cooler Cover Mounting Capscrews 24 Nom 18 ft-lb

Oil Filter Head Mounting Capscrews 24 Nom 18 ft-lb
Oil Cooler Cover Pipe Plugs

10 Nom 74 in-lb
10 N*m 74 in-lb
(3) 36 N*m 27 ft-lb
(4) 45 N*m 35 ft-lb
Oil Pressure Regulator Plug 80 Nom 59 ft-lb
Oil Drain Plug 80 N*m 59 ft-lb
Oil Pan Mounting Capscrews 24 Nom 18 ft-lb

shown. Start at the center of the oil pan and
alternate toward both ends.
Oil Pump Suction Tube Bracket

Suction Tube to Block A 9 Nom 80 in-lb
Brace to Block 9 Nom 80 in-lb
Brace to Suction Tube 9 Nom 80 in-lb
Oil Pump Mounting Capscrews 24 Nom 18 ft-lb

Specifications and Torque Values - Group 18 Cooling System Specifications
Oil Temperature Thermostat 50 N*m 37 ft-lb
Cooling System Specifications

Fan Hub Assembled Height 124.85 mm MIN 4.915 in
125.65 mm MAX 4.946 in
Fan Hub Bearing Installation Force 9000 N MIN 2023 Ibf
Fan Hub Shaft End Clearance 0.15 mm MAX 0.006 in
Radiator Cap Pressure Test A 6

104OC [220°F] (4 103 kPa MIN 15 psi
99OC [210°F] (W 48 kPa MIN 7 psi
Thermostat Operating Temperature

Initial Opening Temperature 81% MIN 178OF
83OC MAX 182OF
Fully Open Temperature 95OC MAX 203OF
Maximum Open Distance 41.5 mm MAX 1.63 in
Viscous Fan Drive Operating Temperature Viscous Fan Drive

Start Modulation 85OC 185OF Operating Temperature
Maximum Speed 93OC 2OO*F
Cooling System Specifications Specifications and Torque Values - Group 18
Cooling System Torque Values

Belt Tensioner Mounting Capscrew 43 N*m 32 ft-lb
Fan Hub Mounting Capscrew 24 Nom 18 ft-lb
Fan Hub Pulley Mounting Capscrews 45 Nom 33 ft-lb
Coolant Inlet Hose Clamps 5 N*m 44 in-lb
Thermostat Housing Mounting Capscrews 24 Nom 18 ft-lb
Water Pump Mounting Capscrews 24 Nom 18 ft-lb
Water Outlet Connection 24 Nom 18 ft-lb

Specifications and Torque Values - Group 18 Cooling System Specifications
Air Intake System Specifications

Intake Air Restriction
Naturally Aspirated 50.8 cm H,O MAX 20.0 in H,O
Turbocharged 63.5 cm H,O MAX 25.0 in H,O
Turbocharger Shaft Radial Clearance (Side

to Side) 0.21 mm MIN 0.008 in
0.46 mm MAX 0.018 in
Note: Specifications and instructions for rebuilding
the turbochargerare provided in the HI Turbocharger
Shop Manual, Bulletin No. 3810321.
Turbocharger Shaft Axial Clearance (End

Clearance) 0.03 mm MIN 0.001 in
0.08 mm MAX 0.003 in
Charge Air Cooler

Differential Pressure Across Cooler 21 kPa MAX 3 psi
Wastegate Actuator Calibration

l Air Pressure 165 kPa MIN 24 psi
179 kPa MAX 26 psi
l Actuator Rod Movement 0.33 mm MIN OOslcl;I;

1.3 mm MAX
Air Intake System Torque Values

Turbocharger Mounting Nut 45 Nom 33 ft-lb
Turbocharger Oil Drain Mounting

Capscrew 24 Nom 18 ft-lb
Cooling System Specifications Specifications and Torque Values - Group 18
Turbocharger Air Crossover Hose Clamps 5 Nom 44 in-lb
Turbocharger Oil Drain Tube Hose Clamps 5 Nom 44 in-lb
Turbocharger Turbine Housing Capscrews 11 N*m 97 in-lb
Turbocharger Compressor Housing Clamp

Nut 8 Nom 71 in-lb
Turbocharger Oil Supply Hose Connection 15 Nom 11 ft-lb
Turbocharger Discharge Elbow Clamp Nut 8 N*m 71 in-lb
Turbocharger Mounting Studs

Use two mounting nuts locked together 10 Nom 89 in-lb
Specifications and Torque Values - Group 18 Exhaust System Specifications
Exhaust System Specifications

Exhaust Restriction 7.5 cm Hg MAX 3.0 in Hg
Exhaust Manifold Flatness 0.20 mm MAX 0.008 in
Exhaust System Torque Values

Exhaust Manifold Mounting Capscrews:
l Flan ed Head 43 N*m 32 ft-lb
l Hex 9-1ead 43 N*m 32 ft-lb
Air Compressor Inspection Specifications

l Single Cylinder Air Compressor 0.05 mm MIN 0.002 in
0.15 mm MAX 0.006 in
l Two Cylinder Air Compressor 0.05 mm MIN 0.002 in
0.19 mm MAX 0.008 in
Note: Specifications and instructions for rebuilding
the two cylinder air compressor are provided in the
Air Equipment Rebuild Manual, Bulletin Nos. 3810242 and 3810257.
Air Compressor Torque Values
Air Compressor Brace to Air Compressor
;t,;;;ing Capscrews
43 N*m 32 ft-lb
Bendix 43 N*m 32 ft-lb
Midland 32 Nom 24 ft-lb
Air Compressor Brace to Cylinder Block

Mounting Capscrew 43 N*m 32 ft-lb
Air Compressor Flange Mounting Nuts

Nut 77 N*m 57 ft-lb
Stud to Gear Housing Hand Tight
Electrical System Specifications Specifications and Torque Values - Group 18
Air Compressor Oil Supply Hose

Connection 15 N*m 12 ft-lb
Air Compressor Coolant Line Connection 35 N*m 26 ft-lb
Electrical System Specifications

Drive Belt 360 N MIN 80 Ibf
Engine has an automatic belt tensioner, no 490 N MAX 100 Ibf
adjustment necessary.
Batteries Specific Gravity State of

at 27% [180°F] Charge
1.260 to 1.280 100%
1.230 to 1.250 75%
1.200 to 1.220 50%
1.170 to 1.190 25%
1.110 to 1.130 Discharged
Electrical System Torque Values

Belt Tensioner Capscrew 44 Nom 32 ft-lb
Alternator Mounting
Ml 0 Capscrew A 44 Nom 32 ft-lb
Lower Support Bracket
M8 Capscrew B 24 Nom 18 ft-lb
Ml 0 Capscrew 44 N*m 32 ft-lb
Mounting Capscrews C 77 Nom 57 ft-lb
Starting Motor Mounting Capscrew 77 Nom 57 ft-lb

Mounting Adaptions - Torque Values Specifications and Torque Values - Group 18
Flywheel Ring Gear Installation
l Temperature 177% 350°F

l Time Interval 30 Min. MIN 30 Min.
6 Hours MAX 6 Hours
Mounting Adaptations - Torque Values

Flywheel Housing Access Plate
Capscrews 24 N*m 18 ft-lb
Flywheel Housing Mounting Capscrews 60 N*m 44 ft-lb
Flywheel Mounting Capscrews 140 N*m 101 ft-lb

Specifications and Torque Values - Group 18 Drive Belt Tension
Drive Belt Tension
I l/2 in.
I 4 rib
3822524 ST-1 138 670 150 270 to 530 60 to 120
3822525 ST-l 293 710 160 290 to 580 65 to 130
3822525 ST-l 293 890 200 360 to 710 8Oto160
I 10 rib 3822525 3823 138 1110 250 440 to 890 100 to 200
I 12 rib 3822525 I 3823 138 I 1330 I 300 I 530 to 1070 I 120to240 I
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
FRACTION, DECIMAL, MILLIMETER CONVERSIONS Specifications and Torque Values - Group 11
Page V-42 614 Serie!
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
INCHES 1 MM I T&i. I T% I N&. I Tk.
0.5313 113.494
0.0781 1 1.984 1 I I -1
0.0938 1 2.381 I I 119 I
0.1094 2.778 39 0.6094 115.478
0.1250 3.175 5
0.1406 3.572 41
0.1563 3.969 21
0.1719 4.366 43
0.1875 4.763 11
0.2031 1 5.159 I 1 I I45
0.2188 I 5.556 I I 123 I
0.2344 5.953 47 0.7344 118.653
0.2500 6.350 (3/4)
0.2656 6.747 49
0.2813 I 7.144 I I 25 I
0.2969 7.541 51
0.3125 7.938 13
0.3281 8.334 53
0.3438 I 8.731 I I 1271
0.8750 122.225
0.8906 122.622
0.4375 I 11.113 I I 15 I ~7
0.4531 I 11.509 I l l 161
0.4688 11.906 31 0.9688 124.606
0.4844 12.303 63
0.5000 12.700 (1 IN1
CONVERSION FACTOR:1 INCH = 25.4MM

Specifications and Torque Values - Group 18 Weight and Measures - Conversion Factor!
814 Series Page V-4
Weig rt and Measures - Conversion F actors
FROM U.S. FROM METRIC

CUSTOMARY TO U.S.
TO METRIC CUSTOMARY
MULTIPLY BY MULTIPLY BY
1 Unit Name Abbr. 1 Unit Name 1 Abbr.
Area 1 sa. inch in’ I sa. millimeters I mm2 645.16
I sa. centimeters I cm2 6.452
I sa. foot fs I sa. meter I m2
Fuel pounds per Ib/hp-hr grams per g/kw-hr 608.277
Consumption horsepower kilowatt hour
hour
Fuel
Performance I
miles per gallon mpg
I kilometers per
liter I
km/l 0.4251 2.3527
wm
I gallons per mile
I liters per
kilometer I
I/km 2.3527 0.4251
Force I Dounds force Ibf I Newton IN 4.4482 0.224609

Length 25.40 0.039370
ti :, 304.801 0.00328
0.746 1,341
psi 6.8948 0.145037
0.29613
0.2488 4.019299
in Hg 1 millimeters of 1 mm Hg 25.40 0.039370

mercury
in H20 millimeters of mm H20 25.40 0.039370
water
I bars bars I kilooascals 1 kPa 100.001 0.00999
bars bars millimeters mm Hg 750.06 0.001333
of mercury
Temperature fahrenheit “F centiarade “C (“F-32) + 1.8 11.8 x “C) + 32
Torque pound force i=t lb Newton-meter N lm 1.35582 0.737562
in lb Newton-meter N lm 0.113 8.850756
Velocitv I miles/hour mph kilometers/hour kph 1.6093 0.6214

gal. liter I 3.7853 0.264179
gal. liter I 4.546 0.219976
in3 liter I 0.01639 61.02545
cubic inch in3 cubic cm3 16.387 0.06102
centimeter
Weight (mass) pounds (avoir.) lb kilograms kg i0.4536 2.204623
Work British Thermal BTU joules j I 1054.5 0.000948
Unit
British Thermal o.ooo2933414
Unit
I horsepower
hours
1.341
Newton-Meter to Foot-Pound Conversion Chart Specifications and Torque Values - Group 18
Newton-Meter to Foot-Pound Conversion Chart
Nom ft-lb Nom f&lb Nom ft-lb

1 8.850756 in-lb 55 41 155 114
5 44.0 in-lb 60 44 160 118
6 53.0 in-lb 65 46 165 122
7 62.0 in-lb 70 52 170 125
8 71.0 in-lb 75 55 175 129
9 80.0 in-lb 80 59 180 133
10 89.0 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 530 ,170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters dive Newton-Meters by 9.803

Specifications and Torque Values - Group 18 Capscrew Markings and Torque Values
Capscrew Markings and Torque Values
A Caution: When replacing capscrew, always use a capscrew of the same measurement and strength as the
capscrew being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrew and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S> Customary capscrews are identified by radial lines stamped on the head of the capscrews.
The following examples indicate how capscrews are identified:
Metric - M&1.25 x 25 U.S. Customary [5/16 x 18 x l-1/2]

M8 1.25 25 5/16 18 l-112
Major Thread Distance Length in Major Thread Number Length in
Diameter in Between Millimeters Diameter in Threads Per Inches
Millimeters threads in Inches Inch
Millimeters
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other section of the manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better torque
with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values Specifications and Torque Values - Group 18
Capscrew Markings and Torque Values - Metric
Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings
Bodv
Size-
0 8.8
Torque
0
10.9
Torque Torque
0
12.9
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb N*m ft-lb Nom ft-lb
6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8
Capscrew Head Markings
These are allSAE Grade 5 (3)line . . \ ’
r \- @ID
Q@cJ @
@ 0
Capscrew Torque - Grade 5 Capscrew Capscrew Torque - Grade 8 Capscrew
Capscrew Body Size Cast Iron Alummum Cast Iron Aluminum
Nom ft-lb Nom f&lb Nom ft-lb Nom ft-lb
l/4-20 ’ 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5116 - 18 20 15 16 12 30 22 16 12
- 24 23 17 19 14 33 24 19 14
318 - 16 40 30 25 20 zz 40 25 20
- 24 40 30 35 25 45 35 25
7116 - 14 60 45 45 35 90 65 45 35
- 20 65 50 55 40 95 70 55 40
112 - 13 95 .70 75 55 130 95 75 55
- 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
- 18 150 110 115 85 210 155 115 85
518 - 11 180 135 150 110 255 190 150 110
- 18 210 155 160 120 290 '215 160 120
314 - 10 325 240 255 190 460 340 255 190
- 16 365 270 285 210 515 380 285 210
718 - 9 490 360 380 280 745 550 380 280
- 14 530 390 420 310 825 610 420 310
l-8 720 530 570 420 1100 820 570 420
- 14 800 590 650 480 1200 890 650 480
Specifications and Torque Values - Group 18 Pipe Plug Torque Values
Pipe Plug Torque Values
Size Torque Torque

Thread Actual Thread O.D. In Aluminum Components In Cast Iron or Steel Components
in in Nom ft-lb Nom ft-lb
l/16 0.32 5 45 in-lb 15 10
l/6 0.41 15 10 20 15
l/4 0.54 20 15 25 20
316 0.66 25 20 35 25
l/2 0.65 35 25 55 40
314 1.05 45 35 75 55
1 1.32 60 45 95 70
l-114 1.66 75 55 115 65
l-1/2 1.90 65 65 135 100
Tap-Drill Chart - U.S. Customary & Metric Specifications and Torque Values - Group 18
Tap-Drill - U.S. Customary & Metric

NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size of approximately 60% and 75% of
full thread depth. Generally, it is recommended of that drill sizes be selected in the 60% range as these sizes will provide about 90% of the potential
holding power. Drill sizes in the 75% range are recommended for shallow hole tapping (less than 1 l/2 times the hole diameter) in soft metal and
mild steel.
be Dlill ize Drill iize Drill ;ize Drill

Tin? 7546
48
Size 75016 Size
caiiii-
rr(lb Size
7.50mm
75% Size
13.25mm
1.95mm 12-24 16 19/64 5/6-l 1 17132
5164 4.5Omm 7.60mm M15xl.5 135Omm
34 47 15 N M15xl.5 13.75mm
2.00mm u5.5x.9 4.6Omm 7.70mm 518-11 35164
M2.5x.45 2.05mm 12-24 12-28 ld M9x1.25 7.75mm Ml6x2 14.M)mm
46 ii 7.8Omm 14.25mm
3-48 3056 45 4.70mm 7.9Omm 518-18 9118
2.10mm M5.5x.9 4.75mm 3/8-16 5/16 Ml6x2 Ml6xl.5 14.5Omm
M2.5x.45 M2.6x.45 2.15mm 12-B 3/16 M9x1.25 M9xl 8.OOmm 518-l 8 37184
356 4-36 12 0 14.75mm
F?Omm 4.80mm 8.10mm M16xl.5 15.Wmm
M2.6x.45 2.25mm 11 M9x1 8.2Omm 19.32
636 4.40 43 490mm P 15.25mm
2.3Omm 10 8.25mm 39164
2.35mm 9 8.30mm M17x1.5 15.50mm
440 448 U6xl 5.00mm 3/8-16 lIB27NPT 21164 w7x1.5 Ml8x2.5 15.75mm
%32 6 84Omm 518
M3x.8 2.40mm 5.lOmm 3l8-24 Q M18x2.5 M18x2 16.OOmm
448 41 l/4-20 7 MlOx1.5 8.50mm M18x2 16.25mm
2.45mm 13l64 8.60mm w-10 41184
40 /
8 R Ml 8x1.5 18.50mm
M3x.6 M3x.5 2.50mm M8xl 5.20mm 3/6-24 8.70mm 3/4-10 M19x2.5 21132
11827NPT 11132 M18x1.5 16.75mm
5-a g U6x.75 ;.25mm MlOxl.25 8.75mm M19x2.5 17.Wmm
M3x.5 2.80mm 5.30mm MlOx1.5 8.80mm 43164
5.40 544 37 w-20 4 S 17.25mm
2.70mm M6x.75 5.4Omm 8.90mm 34-16 3l4-16 11116
5-44 6-32 36 114-28 3 MlOx1.25 MlOxl 9.00mm M2tk2.5 17.50mm
2.75mm 5.50mm T 17.75mm
7164 7132 9.10mm 45164
35 5.6Dmm 23&l M20x2.5 M2@C? 18.Wmm
2.80mm 114-28 MIOXI 9.20mm M20x2 18.25mm
;.7Omm 9.3Omm 23l32
6-32 z 5.75mm 7116-14 U M20x1.5 18SOmm
i%?5x6 2.9Omm 1 9.4Omm 47164
32 5.60mm MllXl.5 9.55mm M20x1.5 18.75mm
M3.5~8 3.Wmm 5.90mm 19.00mm
6-40 31 A F 3l4
3.10mm lFJ64 9.60mm 19.25mm
118 M7Xl ,6.OOmm 9.70mm 7i59 49l64
3.20mm IS 9.75mm M22x2.5 19.50mm
M4x.75 3.25mm ,6.lOmm Milxl.5 9.80mm 718-g 25632
30 ,C 7116-14 W 19.75mm
M4x.7 3.30mm M7xl I6.20mm 9.90mm M22x2.5 Max2 2O.Wmm
M4x.75 3.40mm ID 7116.20 25/64 718-l 4 51/64
M4x.7 8-32 29 u7x.75 ,6.25mm lO.Wmm M22x2 20.25mm
3.50mm ,6.30mm 711520 X M2zxl.5 20.50mm
836 IE M12x1.75 10.20mm 718-14 13ll6
8-32 G4 114 Y 20.75mm
3.60mm M7x.75 ,6.4Omm 13l32 M22xl.5 M24x3 21 .OOmm
8-36 27 ,6.6Omm i! 53164
3.70mm j/16-18 I M12xl.75 M12xl.5 10SOmm 21125mm
26 I;.60mm 112-13 27184 27132
M4.5x.75 3.75mm ,G M12x1.5 M12x1.25 10.75mm M24x3 21.50mm
10-24 I6.70mm Ml 2x1.25 ll.Wmm 21.75mm
358Omm 17164 112-13 7116 55&l
2k U8xl.25 I6.75mm l/4-18NPT M24x2 22OOmm
M4.5x.75 3.9Omm 5/l&16 IH 11.25mm 1”-8 718
23 I6.8Omm 11.50mm M24x2 22.25mm
5132 I6.9Omm 29164 M24x1.5 22.50mm
1 O-24 22 5.1624 I
I 11.75mm 57l64
M5xl 4.00mm M8x1.25 U8xl 7.OOmm 11.50mm l%xl.5 22.75mm
1 O-32 J 1 M-20 29164 M25x2 23.Wmm
:A 7.1Omm 9118-12 15/32 la-12 29132
M5x.9 4.10mm 511624 IK M14x2 12.Wm M25x2 23.25mm
M5xl M5x.8 4.20mm <3132 12.25mm l”Xl2 l’-14 59164
lo-32 19 M8xl 7.20mm 9118-12 31164 M25x1.5 23.50mm
M5x.9 4.25mm 7.25mm Ml4x2 M14xl.5 12.5Omm M2Ox1.5 23.75mm
MSx.8 4.3Omm 7.30mm 9116-18 l/2 l”-14 15/16
18 IL Ml4Xl.5 M14xl.25 12.75mm
11164 7.40mm Ml4xl.25 13.Wmm
17 IU 9116-18 33i64
Service Literature
614 Series
Section L - Service Literature

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO - Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO +
ATTN.
r-l
STREET ADDRESS
TYPE or PRINT I
ONLY .
CITY, STATE, ZIP CODE
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BFWlCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
MODEL NUMBER SERIAL NUMBER
KDC91 D 081696 CURRENT PRICES WILL BE CHARGED

Index
Page X-l
About the Manual .................................. i-2 FanHub ...................... ... . 8-4

Accessory Drive Adapter - Cleaning and Inspection for Reuse 4-5 Pressure Caps .................. ... .8-4
Cleaning ....................................... 4-5 Thermostats ................... . . .8-4
Inspection ...................................... 4-5 Water Pump ................................ .8-4
Accessory Drive Adapter - Exploded view ............... 4-3 Cooling System - Service Tools ................... . 8-2
Accessory Drive Adapter - Rebuild ..................... 4-5 Cooling System Specifications .................... .V-X3
Assembly ...................................... 4-6 Air Intake System Specifications .................. .V-85
Disassembly .................................... 4-6 Air Intake System Torque Values ................. v-35
Accessory Drive - General Information .................. 4-4 Cooling System Torque Values .................. .V84
AccessoryDrive Adapter ........................... 4-4 Crankcase Breather Tube - Cleaning and Inspection
Aftercooler Assembly - Cleaning and Inspection for Reuse . . 10-7 for Reuse .................................... *3-8
Inspection ...................................... 10-8 Cleaning and Inspection ....................... .3-8
Aftercooler Assembly - Rebuild ....................... 1O-8 Crankshaft - Cleaning and Inspection for Reuse ...... . . 29
Air Compressor Inspection Specifications ............... V-37 Crankshaft - Cleaning ......................... . . 29
Air Compressor Torque Values. ....................... V37 Crankshaft - Inspection ........................ . . 30
Air Crossover Tube - Cleaning and Inspection for Reuse ... 10-9 Crankshaft Gear - Replacement . . . . . . .33
Cleaning ....................................... 10-9 Crankshaft Gear - Inspection . . . . . . . .34
Inspection ...................................... 10-9 Crankshaft Gear - Installation . , . . . . . .35
Air Intake System - Exploded View ..................... 10-3 Crankshaft Gear - Removal . . . . . . . .33
Air intake System - General Information ................ lo-4 General Information . . . . . . . . . . . . . . 33
Air Intake System - Service Tools ...................... 10-2 Cylinder Block - Cleaning in a Hot Tank : 15
Air Transfer Pipe - Cleaning and Inspection for Reuse ..... 10-9 Cylinder Block - Cleaning with Solvent ... . 12
Cleaning ....................................... 10-9 Cylinder Block - Disassembly . . , . . . , . ... . 10
Inspection ...................................... 10-9 Cylinder Block - Exploded View ........................ 7
Belt Tensioner Inspection ........................... 8-10 Cylinder Block - General Information .................... 9
Blowby Measurement ............................... 14-7 -Camshaft .................................. . 9
Camshaft Bore Expansion Plug Installation ............... 21 Connecting Pods.. ........................... . 9
Camshaft Bushing Bore - Cleaning ..................... 23 Crankshaft.. ................................ . 9
Camshaft Bushing - Installation ........................ 23 Cylinder Block ............................... . 9
Camshaft Bushing - Removal .......................... 22 Cylinder Liner ............................... . 9
Camshaft - Cleaning and Inspection for Reuse ............ 50 Oil Seals ................................... . 9
Camshaft- Cleaning ............................... 50 Pistons .................................... 1 9
Camshaft Gear - Inspection .......................... 53 Vibration Damper. ............................ . 9
Camshaft-Inspection .............................. 50 Cylinder Block - Inspection For Reuse .............. . 16
Camshaft Gear - Replacement ......................... 54 Cylinder Block - Preparation for Cleaning ........... . 10
Camshaft Gear - Cleaning ........................... 54 Cylinder Block - Service Tools .................... 4
Camshaft Gear - Inspection .......................... 54 Cylinder Head Capscrew - Cleaning and Inspection ... 2-37
Camshaft Gear - Installation .......................... 56 Cleaning ................................... 2-37
Camshaft Gear - Removal ........................... 54 Inspection .................................. 2-36
Cspscrew Markings and Torque Values ................. V-45 Cylinder Head Capscrews - Cleaning and Inspection
Capscrew Markings and Torque Values - Metric .......... V-48 for Reuse .................................... .64
Capscrew Markings and Torque Values - U.S. Customary ... V-48 Cleaning ................................... .64
Component Specifications and Torque Values ............. V-3 Free Length - Measurement ..................... .66
Cylinder Block - Rebuild Specifications ................ V-15 Inspection .................................. .65
Cylinder Block - Torque Values ...................... V-21 Cylinder Head - Cleaning and Inspection for Reuse ... 2-9
Cylinder Head - Rebuild Specifications ................. V-Z Cleaning ................................... 2-9
Engine Assembly - Specifications ...................... V-3 Handling ................................... 2-9
Engine Assembly - Torque Values ..................... V-5 Inspection ..................................... 2-10
Connecting Rod Bearings - Cleaning and Inspection Winder Head - Exoloded View ....................... 2-6
for Reuse ......................................... 39 Cylinder Head - General Information ................... i-8
Connecting Rod Bearings - Cleaning ................... 39 Cylinder Head - Pressure Testing ..................... 2-34
Connecting Rod Bearings - Inspection .................. 39 Cylinder Head - Rebuild ............................ 2-l 1
Connecting Rod Bushing - Replacement ................. 45 Assembly ..................................... 2-26
Inspection ....................................... 49 Cleaning ...................................... 2-12
Installation ....................................... 47 Disassembly ................................... 2-l 1
Machining ....................................... 49 Inspection ..................................... 2-13
Removal ........................................ 45 Valve - Grinding ................................. 2-21
Connecting Rods - Bend and Twist Inspection ............ 43 Valve Guide - Inspection .......................... 2-17
Connecting Rod Alignment - Inspection ................. 44 Valve - Inspection ............................... 2-20
Connecting Rod Twist - Inspection ..................... 44 Valve Seat Insert - Grinding ........................ 2-22
Fixture Calibration ................................. 43 Valve Seat Insert - Inspection ....................... 2-18
Connecting Rods - Cleaning and Inspection for Reuse ...... 40 Valve Spring - Inspection .......................... 2-19
Connecting Rods - Cleaning ......................... 40 Valve Stem Seal - Inspection ....................... 2-19
Connecting Rods - Inspection ........................ 41 Cylinder Head - Service Tools ........................ 2-2
Coolant Filter Shutoff Valve - Cleaning and Inspection Cylinder Head - Vacuum Testing Valve Seating .......... 2-36
for Reuse ....................................... 810 Cylinder Head - Valve Guide Replacement .............. 2-28
Assembly ..................................... 8-11 Assembly ..................................... 2-29
Cleaning ...................................... 8-11 Disassembly ................................... 2-28
Disassembly ................................... 8-10 Inspection ..................................... 2-29
Cooling System Components - Exploded View. ........... 8-3 Cylinder Head - Valve Seat Insert Replacement .......... 2-31
Cooling System - General Information .................. 8-4 Inspection ..................................... 2-33
Belt Tensioner ................................... 8-4 Installation ..................................... 2-33
Cooling Fans .................................... 8-4 Removal ...................................... 2-31
Index
Page X-2
Cylinder Liners - Cleaning and Inspection for Reuse ... . . 24 Starting Motor - Installation ....................... o-82
Cylinder Liners - Cleaning ...................... . . 24 Tachometer Drive - Installation ..................... ‘o-117
Cylinder Liners - Inspection ..................... . . 25 Thermostat and Housing - Installation ............... O-101
Dowel Pins (Cylinder Head) - Removal .............. . . 11 Timing Pin Assembly - Installation .................. 9-69
Drive Belt Tension ............................. . v-41 Turbocharger Exhaust Outlet Connection - Installation ... ‘O-101
Drive Units - Service Tools ....................... . 4-2 Turbocharger - Installation ........................ . O-98
Electrical System Specifications ................... . v-38 Turbocharger Oil Drain Tube - Installation ............ o-99
Electrical System Torque Values .................. . v-38 Turbocharger Oil Supply Hose - Installation ........... ‘O-100
Engine - Assembly ............................. g-39 Valve Arrangement ............................. . g-93
AFC Tube - Installation ......................... ‘o-112 Valve Clearance - Adjustment ...................... . g-92
Aftercooler - Installation ........................ o-97 Valve Cover - Installation ......................... . o-94
Air Compressor - Installation .................... ‘o-119 Valve Tappet - Installation ........................ o-44
Air Crossover Tube - Installation .................. O-101 Vibration Damper - Installation ..................... c-117
Alternator Brace - Installation .................... C-104 Water Pump - Installation ......................... o-67
Alternator - Installation ......................... c-103 Engine Accessories - Installation ................... ‘O-121
Alternator Mounting Bracket - Installation ........... O-103 Engine Components - General Information ............ . . v-2
Belt Tensioner Bracket - Installation ............... O-105 Engine Dataplate - Replacement .................... . . 59
Belt Tensioner - Installation ..................... C-105 Engine Dataplate - Installation ..................... . . 59
Camshaft - Installation ......................... . o-65 Engine Dataplate - Removal ....................... . . 59
Connecting Rod Bolt - Installation ................ o-54 Engine Diagrams ................................ .. 6
Coolant Filter - Installation ...................... ‘O-102 Engine - Disassembly ............................. o-9
Coolant Heater - Installation ..................... o-82 AFC Tube - Removal ............................ : 012
Coolant Inlet Connection - Installation ............. ‘O-103 Aftercooler - Removal ............................ . o-17
Coolant Outlet Connection - Installation ............ O-102 Air Compressor - Removal ........................ . g-14
Coolant Vent Fitting - Installation ................. O-102 Air Crossover Tube - Removal ..................... . o-17
Coolant Vent Petcock - Installation ................ O-102 Alternator Brace - Removal ........................ . g-21
Coolant Vent Tube - Installation .................. O-103 Alternator Mounting Bracket - Removal ............... . g-22
Crankcase Breather Tube - Installation ............. o-95 Alternator - Removal ............................ . o-22
Crankshaft - Installation ........................ . g-47 Belt Tensioner Bracket - Removal ................... . o-21
Cylinder Block - Installation onto Engine Rebuild Stand o-39 Belt Tensioner - Removal ......................... . 6-21
Cylinder Head - Installation ..................... o-85 Camshaft - Removal ............................ . O-28
Cylinder Liner - Installation ...................... cl-40 Coolant - Draining .............................. . Cl-10
Drive Belt - Installation ......................... ‘cl 18 Coolant Filter - Removal ......................... . O-10
Engine Lifting Bracket - Installation ............... o-96 Coolant Heater - Removal ........................ . g-26
Engine - Removal from the Rebuild Stand .......... ‘O-105 Coolant Inlet Connection - Removal ................. . o-24
Engine Support, Front - Installation ............... O-l 18 Coolant Outlet Connection - Removal ............... .9-22
Exhaust Manifold - Installation ................... o-97 Coolant Vent Petcock - Removal ................... . O-23
Fan Hub Assembly - Installation .................. ‘O-196 Coolant Vent Tube Fitting - Removal ................ . O-23
Flywheel Bore Runout Measurement .............. . o-79 Coolant Vent Tube - Removal ..................... . g23
Flywheel Face Runout Measurement .............. . O-81 Crankcase Breather Tube - Removal ................ . g-16
Flywheel Housing - Installation ................... . g-72 Crankshaft - Removal ........................... . g-36
flywheel - Installation .......................... . o-77 Cylinder Head - Removal ......................... . g-23
Fuel Drain Manifold - Installation ................. o-96 Cylinder Liner Carbon Deposits - Removal ............ . O-32
Fuel Filter Head - Installation .................... ‘o-111 Cylinder Liner Protrusion - Checking ................ . o-37
Fuel Filter - Installation ......................... o-111 Cylinder Liner - Removal ......................... . o-37
Fuel Injection Pump - Installation ................. O-106 Drive Belt - Removal ............................ . g-21
Fuel Injection Pump Supply Line - Installation ....... O-110 Engine - Installation onto Engine Rebuild Stand ........ . g-15
Fuel Lines, High Pressure - Installation ............. o-112 Engine Lifting Equipment and Brackets .............. . . o-9
Fuel tines, Low Pressure - Installation ............. o-119 Engine - Preparation for Steam Cleaning ............. . . c-9
Fuel Pump Solenoid - Installation ................. o-119 Engine - Steam Cleaning ......................... . . c-9
Fuel Transfer Pump - Installation ................. O-l 18 Engine Support, Front - Removal ................... . g-31
Gear Cover - Installation ........................ O-l 16 Exhaust Manifold - Removal ....................... . O-20
Gear Housing - Installation ...................... . o-62 Expansion Plug - Removal ........................ . 539
Injector - Installation ........................... o-95 Expansion Plug - Replacement .................... .538
Intake Manifold Cover - Installation ................ . g96 Fan Hub Assembly - Removal ..................... . O-24
Lubricating Oil Cooler - Installation ................ o-84 Flywheel Housing - Removal ...................... . g-27
Lubricating Oil Filter - Installation ................. . o-85 flywheel - Removal ............................. . g-27
Lubricating Oil Pan - Installation .................. o-68 Fuel Drain Manifold - Removal ..................... . O-18
Lubricating Oil Pump - Installation ................ g-64 Fuel Filter Head - Removal ........................ . 9-11
Lubricating Oil Suction Tube - Installation .......... . c-68 Fuel Filter - Removal ............................ . o-11
Main Bearing (Lower) - Installation ................ . O-47 Fuel Injection Pump - Removal .................... . g-13
Main Bearing (Upper) - Installation ................ . o-46 Fuel Injection Pump Supply Line - Removal ........... . g-12
Main Bearing Cap - Installation .................. o-47 Fuel tines, High Pressure - Removal ................ . g-12
Piston Assembly - Installation .................... . g-58 Fuel tines, Low Pressure - Removal ................. . O-11
Piston Cooling Nozzle - Installation ............... . o-45 Fuel Pump Solenoid - Removal .................... . o-15
Piston Pin - Installation ........................ . g-54 Fuel Transfer Pump - Removal ..................... . o-11
Piston Ring End Gap - Measurement .............. . g-55 Gear Cover - Removal ........................... . O-26
Piston Ring - Installation ....................... . g-56 Gear Housing - Removal ......................... . o-31
Push Rod - Installation ......................... c-89 Injector - Removal .............................. . O-18
Rocker Lever and Shaft - Assembly ............... o-89 Intake Manifold Cover - Removal ................... . o-17
Rocker Lever Assembly - Installation .............. o-91 Lubricating Oil Cooler - Removal ................... . O-24
Seal, Front Crankshaft - Installation ............... ‘o-113 Lubricating Oil - Draining ......................... . O-10
Seal, Rear Crankshaft - Installation ................ . o-51 Lubricating Oil Filter - Removal .................... . O-10
index
Page X-3
Lubricating Oil Pan - Removal ....................... g-27 Expansion Plug - Installation .......................... 19
Lubricating Oil Pump Gear Backlash - Measurement ...... O-30 Pipe Plug - Installation .............................. 20
Lubricating Oil Pump - Removal ..................... O-31 Fan Hub - Cleaning and Inspection for Reuse ............ 8-7
Lubricating Oil Suction Tube - Removal ................ O-27 Cleaning ....................................... 8-7
Main Bearing (Lower) - Removal ..................... O-36 Inspection ...................................... 8-8
Main Bearing (Upper) - Removal ..................... O-36 Fan Hub - Rebuild .................................. 8-8
Main Bearing Cap - Removal ........................ ME Assembly ...................................... 8-9
Piston Assembly - Removal ......................... O-33 Disassembly .................................... 8-8
Piston Cooling Nozzle - Removal ..................... O-36 Flexplate Assembly - Cleaning and Inspection for Reuse ... 16-6
Piston Pin - Removal .............................. O-34 Flywheel - Cleaning and Inspection for Reuse ............ 165
Piston Ring - Removal ............................. O-35 Cleaning ....................................... 165
Push Rod - Removal .............................. g19 Inspection ...................................... 16-5
Rocker Lever Assembly - Removal .................... O-19 Flywheel Housing - Assembly (Wet Clutch Application) ..... 16-8
Seal, Front Crankshaft - Removal ..................... O-26 Flywheel Housing - Cleaning and Inspection for Reuse ..... 167
Seal, Rear Crankshaft - Removal ..................... O-28 Cleaning ....................................... 16-7
Starting Motor - Removal ........................... O-26 Inspection ................................. . 167
Tachometer Drive - Removal ........................ g-13 Flywheel Ring Gear - Replacement ............... . 16-6
Thermostat and Housing - Removal ................... O-22 Installation ................................. . 16-6
Turbocharger Exhaust Outlet Connection - Removal ....... O-16 Removal .................................. .16-6
Turbocharger Oil Drain Tube - Removal ................ O-20 Free Length - Measurement ..................... 2-39
Turbocharger Oil Supply Hose - Removal ............... O-20 Fuel Drain Manifold - Inspection ................. . 6-16
Turbocharger - Removal ........................... O-20 Fuel Injection Pump Gaskets and Seals - Replacement 511
Valve Cover - Removal ............................. O-18 Fuel Injection Pump - Idle Speed Adjustment ........ 1425
Valve Tappet - Removal ............................ O-29 RSV Governor .............................. 1425
Vibration Damper - Removal ........................ O-25 RQV and RQVK Governor ..................... 14-28
Wastegate Actuator Hose - Removal ................... O-16 Fuel Lines, High Pressure - Cleaning and Inspection
Water Pump - Removal ............................ C-25 for Reuse ................................... . 6-14
Cylinder Block - Removal from Engine Rebuild Stand ...... O-39 Fuel Lines - Cleaning and Inspection ............. * 615
Engine Disassembly and Assembly - Service Tools ......... O-4 General Information .......................... * 614
Engine Dynamometer Test - Engine Run-In ............. 14-17 Fuel Lines, Low Pressure - Cleaning and Inspection
Engine Dynamometer Test - Installation of the Engine ..... 14-9 for Reuse ................................... . 616
Engine Dynamometer Test - Performance Checking ...... 14-21 Fuel System - General Information ................ . 5-2
Engine Identification ................................. 2 Derivative Fuel Injection Pump - Data Tag Information . . . . . 5-3
Engine Dataplate .................................. 2 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Fuel Injection Pump Dataplate ........................ 3 Fuel Injection Pump - Data Tag Information . . . . . . . . . . . . . 5-2
Engine Lifting Brackets - Cleaning and Inspection Fuel Injection Pump - Data Tag Location ....... . 5-2
for Reuse ......................................... 66 Fuel Shutoff Solenoid - Wiring Requirements .... 5-3
Engine Painting .................................. 14-26 Governor - Data Tag Information ............. : 53
Engine Run-In Procedure - “In-Chassis” ............... 1424 Fuel Systems - Rebuild Specifications .......... . v-25
Engine Run-In - General Procedures ................... 14-8 Fuel Injection Pump Sealing Washer .......... . v-27
Engine Storage - Long Term ......................... 14-29 Fuel Shutoff Solenoid Adjustment ............ . v-27
Engine Removal from Long Term Storage ............. 14-32 Fuel System Specifications ................. . v-25
Engine Storage - Short Term ........................ 14-27 Fuel System Torque Values ................. . v-27
Engine Removal From Short Term Storage ............ 14-29 Fuel Transfer Pump - Exploded View ........... .5-4
Engine Support Bracket, Front - Cleaning and Inspection for Fuel Transfer Pump - Rebuild ................. . 5-5
Reuse.. ....................................... ..16- 9 Cleaning ............................... . 55
Cleaning ....................................... 16-9 Assembly .............................. ... . 5-5.
Inspection ...................................... 16-9 Gear Cover - Cleaning and Inspection for Reuse . . . . * * . 60
Engine Testing - Component Identification and Diagrams ... 14-3 Gear Cover - Cleaning ..................... ... . . 60
Engine Testing - General Information ................... 14-5 Gear Cover - Inspection .................... ... . . 60
Engine Dynamometer Run-in ........................ 14-5 Gear Housing - Cleaning and Inspection for Reuse . . . . 57
In-Chassis Run-In ................................. 14-5 Gear Housing - Cleaning ................... . . . . . . 57
Engine Testing - General Specifications ................ 14-6 Gear Housing - Inspection .................. . . * . , . . . 57
Engine Testing - Service Tools ........................ 14-2 General Cleaning Instructions . . . i-8
Engine Testing - Test Specifications ................... V-39 Solvent and Acid Cleaning .... . i-8
Exhaust Manifold - Cleaning and Inspection for Reuse .... 11-4 Steam Cleaning ............ .... . i-8
Cleaning ...................................... 1 l-4 General Engine Specifications . . .... . 4
Inspection ..................................... 11-4 Cooling System ............ .... .. 5
Exhaust Manifold - Exploded View .................... 11-2 Fuel System .............. .... .. 5
Exhaust Manifold Outlet Connection - Cleaning and Inspection General Engine Data ........ .. 4
forReuse ....................................... 11-6 Intake Air and Exhaust System . .. 5
Cleaning ...................................... 1 l-6 Lubrication System .................. 4
Inspection ..................................... 116 General Engine Test Procedure - In Chassis ‘1423
Exhaust Manifold Turbocharger Mounting Stud - General Information ................... . . (18
Replacement ..................................... 11-5 Disassembly ....................... . . oa
Inspection ..................................... 11-5 Assembly ......................... . . 08
Installation ..................................... 11-5 General Repair Instructions ............. . i-7
Removal ...................................... 11-5 General Safety Instructions ............. . i-6
Exhaust System - General Information ................. 11-3 Generic Symbols ..................... . i-4
Exhaust Manifold ................................ 11-3 Glossary of Terms .................... . i-9
Exhaust System Specifications ........................ V-37 How To Use This Manual ............... . i-3
Exhaust System Torque Values ....................... V-37 Group Contents ..................... . i-3
Index.. ........................... . i-3
index
PageX-4
Metric Information, ................................ i-3 Inspection ...................................... 7-8

Table of Contents ................................ i-3 Pipe Plug Torque Values ............................ V-47
Mustrations.. ..................................... i-5 Pistons - Cleaning and Inspection for Reuse .............. 27
Injector - Chatter Testing ............................ 6-14 Piston Rings - Removal ............................. 27
injector - Spray Testing ............................. 6-l 3 pistons - Cleaning ................................. 27
Injectors and Fuel Lines - Exploded view ................. 6-6 Pistons - Inspection ................................ 28
Injectors and Fuel Lines - Exploded View ................. 6-3 Push Rods - Cleaning and Inspection for Reuse ........... 4-4
Injectors and Fuel Lfnes - Exploded View ................. 6-5 Cleaning ...................................... ..4 -4
Injectors and Fuel Lines - General Information ............ 6-7 Inspection ....................................... 4-4
Injectors and Fuel Lines - Service Tools ................. 6-2 Rear Cover - Cleaning and Inspection ................... 63
Injectors - Cleaning and Inspection for Reuse ............. 6-8 Cleaning ........................................ 63
General Information ................................ 6-8 Inspection ....................................... 64
Injector - Assembly ............................... 6-12 Rocker Assembly Oil Manifold - Cleaning and Inspection for
Injector - Cleaning and Inspection .................... 6-10 Reuse ........................................... 3-7
Injector - Disassembly .............................. 6-8 Cleaning ....................................... 3-7
Intake Manifold Cover - Cleaning and Inspection for Reuse . 10-7 Inspection ...................................... 3-7
Inspection ...................................... 10-7 Rocker Lever Assembly - Cleaning and Inspection ........ 3-4
Lubricating Oil Dipstick - Calibration .................. 7-13 Assembly ...................................... 3-6
Lubricating Oil Pan - Cleaning and Inspection for Reuse ... 7-5 Cleaning ....................................... 35
Cleaning ....................................... 7-5 Disassembly .................................... 3-4
Inspection ...................................... 7-5 Inspection ...................................... 3-5
Lubricating Oil Pump - Cleaning and Inspection for Reuse . 7-14 Rocker Lever Assembly - Exploded view ................ 3-2
Cleaning ...................................... 7-15 Rocker Lever Assembly - General Information ............ 3-3
Disassembly ................................... 7-14 Rocker Lever Assembly - Rebuild Specifications .......... V-25
Inspection ..................................... 7-l 5 RQVN Governor Fuel Shutoff Solenoid - Adjustment ....... 5-9
Lubricating Oil System - Exploded View ................. 7-4 RSV Governor Fuel Shutoff Solenoid - Orientation and
Lubricating Oil System - General Information ............ 7-3 Adjustment ....................................... 5-6
Dipstick ........................................ 7-3 Fuel Shutoff Solenoid . Adjustment ................. . 5-8
Lubricating Oil Cooler and Filter Head ................. 7-3 Fuel Shutoff Solenoid . Orientation .................. .5-6
Lubricating Oil Pump .............................. 7-3 Shutdown Lever or Spring - Replacement ............. 5-10
Oil Filter Head ................................... 7-3 Tap-Drill Chart - U.S. Customary & Metric ............. . V-48
Oil Pan ........................................ 7-3 Thermostat Housing - Cleaning and Inspection for Reuse . . 86
Oil Pressure Regulator ............................. 7-3 Cleaning ..................................... .8-6
Oil Temperature Thermostat ........................ 7-3 Inspection .................................... .8-6
Lubricating Oil System - Service Tools. ................. 7-2 Thermostat - Inspection ........................... . 8-6
Lubricating Oil System Specifications .................. V-30 Turbocharger - Cleaning and Inspection for Reuse ...... . lo-5
Lubricating Oil System Torque Values .................. V-31 Inspection .................................... . lo-5
Lubricating Oil Temperature Thermostat - Cleaning and Valve Cover - Cleaning and Inspection for Reuse ....... . 3-8
Inspection ....................................... 7-12 Cleaning ..................................... . 3-8
Cleaning ...................................... 7-12 Inspection ................................ 3-8
Inspection ..................................... 7-12 Valve Tappet Cleaning and Inspection for Reuse .... . 4-3
Main Bearing Caps and Capscrews - Cleaning and Inspection for Cleaning ................................. ... . 4-3
Reuse ............................................ 38 Inspection ................................ ... 4-3
Cleaning ........................................ 38 Valve Tappet - Rebuild Specifications ............ .. b-25
Inspection ....................................... 39 Valve Tappets and Push Rods - Exploded View ..... ... . 4-2
Main Bearings - Cleaning and Inspection for Reuse ........ 36 Valve Tappets and Push Rods - General Information . . . . . 4-3
General Information ................................ 36 Vibration Damper - Cleaning and Checking for Reuse . . . . 61
Main Bearings - Cleaning ............................ 37 General Information ......................... . 61
Main Bearings - Inspection ........................... 37 Rubber Element Vibration Damper . Inspection .... . 61
Thrust Bearings - Inspection .......................... 38 Rubber Vibration Damper - Cleaning ................... 61
Mounting Adaptations - Exploded View ................. 16-3 Viscous Vibration Damper - Cleanina ................... 62
Mounting Adaptations - General Information ............. 16-4 Viscous Vibration Damper - Inspecti& ................ . 62
Rywheel and Ring Gear ............................ 16-4 Water Outlet Connection - Cleaning and Inspection
Flywheel Housing ................................ 16-4 for Reuse ....................................... 8-7
Mounting Adaptations - Service Tools .................. 16-2 Water Pump Assembly - Cleaning and Inspection for Reuse 8-5
Mounting Adaptations Specifications ................... V-39 Cleaning ...................................... 8-5
flywheel Housing (Wet Application) ................... V-39 Inspection ..................................... 8-5
flywheel Ring Gear Installation ...................... V-40 Weight and Measures - Conversion Factors ............ v-43
Mounting Adaptations - Torque Values ................. V-46
Newton-Meter to Foot-Pound Conversion Chart .......... V-44
Oil Cooler Cover - Disassembly and Assembly .......... 7-10
Assembly ..................................... 7-11
Cleaning ...................................... 7-10
Disassembly ................................... 7-10
Oil Cooler Element - Cleaning and Inspection for Reuse .... 7-6
Cleaning ....................................... 7-6
Inspection ...................................... 7-6
Pressure Test .................................... 7-6
Oil Filter Bypass Valve - Replacement .................. 7-9
Oil Pressure Regulating Valve - Cleaning and Inspection ... 7-7’
Assembly ...................................... 78
Cleaning ....................................... 78
Disassembly .................................... 7-7
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
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KDC 614 Series Engine Shopmanual 1991 SERIES: Cebm614Sho

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CEBM614SHO

KDC 614 SERIES ENGINE

KDC 614 Series Engine

Engine Disassembly and Assembly - Group 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Cylinder Block - Group 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Cylinder Head - Group 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Rocker Levers - Group 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cam Followers - Group 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel System - Group 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Injectors and Fuel Lines - Group 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Lubricating Oil System - Group 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cooling System - Group 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Drive Units - Group 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Intake System - Group 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Exhaust System - Group 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Air Equipment - Group 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical Equipment - Group 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine Testing - Group 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Instruments and Controls - Group 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mounting Adaptations - Group 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Specifications and Torque Values - Group 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Aboutthe Manual .......................................................... i-2

General Cleaning Instructions .................................................. i-8

General Repair Instructions i-7

General Safety ‘Instructions i-6

Generic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-4

Glossary of Terms . . . . . . i-9

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-3

About the Manual

Each group contains the following in sequence:

l An Alphabetical Table of Contents (Index).

l Exploded view(s) of all the components in the group.

How To Use This Manual

Each group contains the following information:

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step,

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque,

PERFORM an electrical MEASUREMENT.

The illustrations used in the “Repair Sections” of this manual

The illustrations are intended to show repair or replacement

General Safety Instructions

General Repair Instructions

General Cleaning Instructions

D. C.: Direct Current

E. S. N. Engine Serial Number

Hammer: A hand tool consisting of a hard steel head on a handle.

I. D.: Inside Diameter

MIN: Minimum allowed

O.D.: Outside Diameter

Section E - Engine and Component Identification

Engine Diagrams ............................................................ 6

Engine Identification ......................................................... 2

General Engine Specifications ................................................... 4

ENGINE SERIAL NO.

The KDC model designation represent the basic design

Fuel Injection Pump Dataplate

The Bosch Injection pump dataplate contains:

9 400 230 097

The vendor part number for the fuel pump-governor