SENR9778-02 83 Perkins’ a Specifications 1103 and 1104E Engines DEwTEngine) DDTEnging Dalene Re tengo) RG'fEngine) gino: RR{Engine) FOLEY ENGINES 1-800-233-6539 Visit Us www.foleyengines.comImportant Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can offen be avoided by recognizing potentially hazardous situations before an accident occurs. A person must 2¢ alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. if these hazard wamings are not heeded. bodily injury or death could occur to you or to other persons. ‘The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word" such as “DANGER’, ‘WARNING’ or “CAUTION”. The Safety Alert ‘WARNING’ label is shown below. ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the warning explains the hazard and can be either written or pictorially presented. (Operations that may cause product damage are identified by “NOTICE” labels on the product and in ‘this publication. Perkins cannot anticipate every:passible circumstance that might Involve.aipotenitial hazard. ‘The warnings in this publication and on the product are, therefore, not all inclusive. Ifa tool, procedure, workimethod br opetating Technique tnaCis hot Specifically Tecommended by Perkins Is used, you must satlsty yoursolf that It Is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. ‘The information, specifications, and illustrations in this publication are on the basis of information that ‘was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other temss can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job: Perkins'dealersihave'the mosticurrentinformation available. When replacement paris are required for this product Perkins recommends ising Perkins replacement parts -or-parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. van lead ty prema ture failures, product damage, personal injury or death.SENR9778-02 Table of Contents Specifications Section Engine Design Fuel Injection Lines Fuel Injection Pump (Delphi DP210 DPA and DPG fuel injection pumps) 5 Fuel injection Pump (Bosch EPVE for the 1104 engines oniy)... 6 Fuel Injection Pump (Beh Sty a 7 Fuel Injectors svnninnnnnnnnnnns B 8 9 9 Fuel Transfer Pump nnn Lifter Group ..... vn Rocker Shaft vn Valve Mechanism Cover Cylinder Head Valves .. Cylinder Head ‘Turbocharger Exhaust Manifold Camshaft... ‘Camshaft Bearings Engine Oil Filter Engine Oil Pump conn Engine Oil Pressure 19 Engine Oil Bypass Valve Engine Oil Pan Crankcase Breather Water Temperature Regulator and Housing Water Pump. Cylinder Block .. Crankshaft Crankshaft Seals, en ‘Connecting Rod Bearing Journal . Main Bearing Journal... ‘Connecting Rod vn Piston and Rings vn Piston Cooling Jet Front Housing and Covers Gear Group (Front)... Flywheel eel Crankshaft Pulley Fan Drive vn Engine Lifting Bracket Altemator ..... a Starter Motor . Glow Plugs Index Section Index ee svn: 43 Table of Contents4 Specifications Section Specifications Section Engine Design Four Cylinder Engine ‘SENR9778-02 When the camshaft is viewed from the front of the engine, the camshaft rotates in the following direction: Clockwise The front of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder. Three Cylinder Engine oe istration omar isration2 ‘wonone7 ‘yindor and vatvo locaton Cytnder and vate locaton (A) tot vata (A) Ina valve (Bd Fiat vale {6) Fata se BOE en vse 105 mm (4.133 inch) BOLE eens 105 mem (4.133 inch) ‘Stroke 127 mm (6.000 inch) SHORE os .. 127 mm (6.000 inch) Displacement 44 L (269 in’) Displacement eeceneene 3.3L (201 in?) Cylinder arrangement oe neeneee Inne Cylinder arrangement .. Indine ‘Type of combustion. _ Direct injection Type of COMbUSHION «en nenenne Direct injection Compression ratio Compression ratio Naturally aspirated engines .....- 19.8:4 Naturally aspirated en 19.31 Turbocharged engines .. 18.2: Turbocharged engines .. 18.21 Turbocharged engines . Turbocharged engines 2 ATA Number of cylinders Number of eylinders, 3 Valves per cylinder Valves per cylinder... 2 Valve lash Valve lash Inlet valve ---x 0.20 mm (0.008 inch) Inlet valve 10.20 mm (0,008 inch) Exhaust valve 45 mm (0.018 inch) Exhaust val (0.45 mm (0.018 inch) Firing order -1,3,4,2 Fring ofder wo 42,3 When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction: . Clockwise When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following iECHION: ensnnrnnnrnnnnenenee CIOCKWISESENR9778-02 When the camshaft is viewed from the front of the engine, the camshaft rotates in the following direction: .. ‘ . Clockwise The front of the engine is opposite the flywheel end, ‘The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder. | typical fuel tne (1) Tighten the union nuts for the fuel injector to the following torque. 30 Nim (22 Ib ft) Note: Tighten the union nuts at the fuel injection ‘pump to the following torque.30 N'm (22 Ib ft) vo2195905 Fuel Injection Pump (Delphi DP210 DPA and DPG fuel injection pumps) Delphi DP210 Note: Before the fuel injection pump is removed from the engine the fuel injection pump shaft must be locked. Position the engine to TC compression stroke of number one cylinder before tightening the locking ‘screw. The locking screw will prevent the shaft from rotating. If the fuel injection pump was removed prior to correctly timing the engine and locking the shaft, the fuel injection pump will need to be timed by trained personnel. Specifications Section ‘stration 4 sposzasay ‘The Delhi DP 210 fuel injection purnp Note: The solenoid on the fuel injection pump is a serviceable item. The fuel injection pump is 2 nonserviceable item. (1) O-ring (2) Locking screw (3) Washer Locking the shaft Loosen locking screw (2) and move the washer (3) to the locked position. Tighten the bolt to the following torque. evens 17 Nem (12 1B) Unlocking the shaft Loosen locking screw (2) and install the washer 3) to the unlocked position. Tighten the bolt to the following torque. 42 Nm (9 bf) stration 5 so0oeess1 Support bracket (4) Tighten the mounting bolt to the following LOFQUE ree 44 Nem (32 Ib f) (5) Tighten the mounting bolt and the nut to the following torque. 22Nm(16 Ib ft)6 Specifications Section Note: The support bracket must be installed after the coolant pump is installed. In order to stop the distortion of the timing case, finger tighten the bolt (4) and then tighten the nut and bolt (5). Tighten the bolt (4), Tighten the bolts that hold the fuel pump to the front housing to the following torque. ...... 25 Nem (18 Ib ft) Delphi DPA ‘The DPA injection pump has a support bracket that is similar to the DP 210 injection pump. ‘SENR9778-02 Fuel Injection Pump (Bosch EPVE for the 1104 engines only) Note: Before the fuel injection pump is removed from the engine the fuel injection pump shaft must be locked. Position the engine to TC compression stroke of number one cylinder before tightening the locking screw will prevent the shaft from rotating. If the fuel injection pump was removed prior to properly timing the engine and locking the shaft, the fuel injection pump will need to be timed by trained personnel. imustration 6 on28o (1) Support rackot (2) Locking screw (6) Washer Note: The torque for the locking screw on the Delphi 'STP fuel injection pump and the Delphi DPA and DPG fuel injection pump is equal. The support bracket is larger on the Delphi DPA fuel injection pump. The torque for the mounting bolts on the support bracket for both fuel injection pumps is equal. Delphi DPG ‘The DPG injection pump is only installed on engines. that operate at a fixed speed. The support bracket is ‘not installed on this injection pump. stration 7 coms Bosch EPVE ful injoction pump Noto: The solenoid on the fuel injection pump is a serviceable item. The fuel injection pump is a nonserviceable item. (1) Ong (2) Locking screw (8) Spacer Locking the shaft Remove spacer (3) before locking screw (2) is tightened to the following torque. ie t 0 Unlocking the shaftSENR9778-02 Loosen the bolt and place spacer (3) behind locking screw (2). Tighten the bolt to the following, torque. .. + 12.Nem (9 Ib ft) The lift of the ER fuel injection pump plunger 1.55 mm (0.0610 inch) Iustration | ‘0888408 Iniallod EVEP fuolnjocton pump (4) Tighten the plug for the fuel injection pump plunger to the following torque. 29Nm (21 Ib) Imastration 9 ‘0885295 ‘Suppor bracket Note: The support bracket must be installed after the coolant pump is installed. In order to stop the distortion of the timing case, finger tighten the bolt (G) and then tighten the nut and the bolt (6). Tighten the bolt (5). (6) Tighten the bolt to the following torque. ... 44 N-m (22 Ib f) (6) Tighten the nut and the bolt to the following torque. . 22Nm (16 lb ft) 7 Specifications Section Tighten the bolts that hold the fuel pump to the front housing to the following torque. ..... 25 N-m (18 Ib ft) sox074902 Fuel Injection Pump (Delphi STP) Note: Before the fuel injection pump is removed from the engine the fuel injection pump shaft must be locked. Position the engine to TC compression stroke of number one cylinder before tightening the locking screw. The locking screw will prevent the shaft from rotating. If the fuel injection pump was removed prior to correctiy timing the engine and locking the shaft, the fuel injection pump will need to be timed by trained personnel. ‘stration 10. sriostros ‘The Delphi STP fue! inection pump Note: The solenoid on the fuel injection pump is a serviceable item. The fuel injection pump is a nonserviceable iter (1) Locking screw (2) Washer Locking the shaft Loosen locking screw (1) and move the washer (2) to the locked position. Tighten the bolt to the following torque. wwe vnn-n 13 Nem (10 Ib R) Unlocking the shaft Loosen locking sorew (2) and install the washer (3) to the unlocked position. Tighten the bolt to the following torque. 12 N-m (9 Ib ft).8 ‘Specifications Section Imustration 11 Support bracket (4) Tighten the mounting bolt to the following torque. ..... svneneee 44 Netm (32 Ib ft) (8) Tighten the mounting bolt and the nut to the following torque. soo 22.Nem (16 Ib ft) Note: The support bracket must be installed after the coolant pump is installed. In order to stop the distortion of the timing case, finger tighten the bolt (@) and then tighten the nut and bolt (5). Tighten the bolt (4). Tighten the bolts that hold the fuel pump to the front housing to the following torque. ..... 25 Nem (18 Ib ft) Fuel Injectors Inustraon 12 Fuel injector damp (1) Tighten the bolt in the clamp for the fuel injector to the following torque. 36 Nim (26 Ib ft) ‘The fuel injector should be tested at the pressure in Table 1. ‘SENR9778-02 Leakage in 10 seconds drops Tablet Service setting for the Fuel Injector Injection Pressure 29.4 + 0.8 MPa (4264 + 116 psi) sor957629 Fuel Transfer Pump Iwistraton 19 (1) Retaining bolts (2) Clip (@) Spacer (4) Fuel transfer pump Type (6) Fuel fiter element (6) Oring (7) Fuel filter bowl .. 12 oF 24 volt electric motorSENR9778-02 Note: Tighten the fuel filter bow! by hand. Rotate the bowl 1/8 of a turn more by hand. Lifter Group mustration 14 0625499, (1) Diameter of the lifter body ... 18.99 to 19.01 mm (0.7475 to 0.7485 inch) Clearance of the lifter in the cylinder block bore... 0.04 to U.09 mm (0.0016 to U.0U3/ inch) ‘01092700 Rocker Shaft Note: The rocker shaft assembly for the 3 cylinder ‘engine and the rocker shaft assembly for the 4 cylinder engine use the same components. The exception is the length of the rocker shaft. istration 15 gosesi74 “Tho rockor shat Note: In order to install the rocker shaft assembly, the tool 27610227 Spacing Toolis required. 9 Specifications Section (1) Snap ring (2) Washer (8) Rocker arm (4) Rocker arm bore Diameter of the rocker arm bore for the bushing 25.01 to 25.05 mm (0.9847 to 0.9862 inch) Rocker arm bushing Clearance between the rocker arm bushing and the rocker shaft. 0.03 to 0.09 mm (0.0010 to 0.0035 inch) Maximum permissible clearance between the rocker arm bushing and the rocker shaft con .. 0.17 mm (0.007 inch) (5) Spring Note: Install the longest screw at the front of the rocker shaft assembly, (6) Tighten the screws evenly. Begin in the center ‘and work toward the outside. Tighten the screws. to the following torque. 35 Nem (26 Ib f) (7) Rocker shaft Diameter of the rocker shaft... 24.96 to 24.89 mm (0.9827 to 0.9839 inch) (8) In order to install the rocker shaft assembly, ‘ensure that the machined square is to the top of the rocker shaft. (8) Locknut Torque for the locknut10 Specifications Section Valve Mechanism Cover The Cover for the Four Cylinder Engine Iustraton 16 onsoKort Cover Tighten the bolts for the valve mechanism cover in the sequence that is shown to the following torque. verneeens ONE T Ub f) The Cover for the Three Cylinder Engine Inustraon 17 gpr0resi9 cover SENR9778-02 Tighten the bolts for the valve mechanism cover in the sequence that is shown to the following torque. ONm(7 bf) Cylinder Head Valves Iustraton 18: Cross soction of cyindor head (1) Valve spring Naturally aspirated engines The installed length of the valve springs sss 33.5 mm (1.318 inch) “The load forthe installed valve springs ... 254 N G77) Turbocharged engines The installed lenath of the valve SPFINQS .....cseesereeesesseeeeee 34.5 mm (1.358 inch) ‘The load for the installed valve spring ....... 229 N (51.4 Ib) (2) Valve spring recess (8) The finished valve guides Inside diameter of valve ‘guide vvsvees 9,000 t0 9.022 mm (0.3543 to 0.3552 inch) Outside diameter of the exhaust valve ‘guide 13,034 to 13.047 mm (0.5131 to 0.5137 inch)SENR9778-02 Outside diameter of the inlet valve guide 13.034 to 13.047 mm (0.5131 to 0.5137 inch) Interference fit of valve guide in cylinder head ..... exe» 0,007 to 0.047 mm (0.0003 to 0.0019 inch) 51.00 to 51.50 mm (2.018 to 2.027 inch) Projection of the valve guide above the valve spring recess (2) 12.35 to 12.65 mm (0.486 to 0.488 inch) Length of Valve guide Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat inserts are installed in the cylinder head. The guides and inserts are then cut and reamed in one operation with special tooling. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a seal that is tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures. (4) Exhaust valve Diameter of the exhaust valve stem cnn vv 8.988 to 8.960 mm (0.3519 to 0.3528 inch) Clearance of valve in valve guide... 0.040 to 0.840 mm (0.0016 to 0.033 inch) ‘Overall length of the exhaust valve ..... 128.92 to 129.37 mm (5.075 to 5.093 inch) ‘The face of the exhaust valve is recessed below the cylinder head by the following amount. Naturally aspirated engines ........ 0.53 to 0.81 mm (0.621 to 0.032 inch) Service limit . 1.06 mm (0.042 inch) . 1.6310 1.81 mm (6.060 to 0.071 nen) Turbocharged engines Service limit .. 2,06 mm (0.0811 inch) (6) Inlet valve Diameter of the inlet valve stem 8.953 to 8.975 mm (0.3525 to 0.3533 inch) Clearance of valve in valve guide .. 0.025 to 0.089 mm (0.001 to 0.0027 inch) Overall length of the inet 128.92 to 129.37 mm (5.075 to §.093 inch) 1" Specifications Section ‘The face of the inlet valve is recessed below the cylinder head by the following amount. 1. 0.58 to 0.84 mm (0.023 to 0.033 inch) Naturally aspirated engines Service limit 1.09 mm (0.043 inch) Turbocharged engines sevens 1,58 t0 1.84 mm (0.062 to 0.072 inch) Service limit cnn 2.09 mm (0.0823 Inch) (6) Exhaust valve face angle from the vertical axis Valve £208 angle. ccrnnenneene 30 degrees: Valve seat angle .. 30 degrees (7) Diameter of the exhaust VaIVE REDD err, 41.51 10 41.75 mm (1.634 to 1.843 inch) (8) Diameter of the head of the inlet ve ... 48.20 to 46.45 mm (1.818 to 1.828 inch) (@) Angle of the inlet valve face from the vertical axis Valve face angle .. . 30 degrees Valve seat angle .. 30 degrees ‘The valve lash is the following value when the engine is cold: Inlet VaIVeS «nn Exhaust valves (0.20 mm (0.008 inch) (0.45 mm (0.018 inch) ‘stration 19 gp0sns0%6 Recess forthe valve seat insert (10) Machine the recess in the head for valve seat Inserts to the following dimensions. Recess for Inlet Valve Seat for Naturally Aspirated Engines (A). 8.910 to 10.040 mm (0.3901 to 0.3952 inch) 6) 47.820 to 47.845 mm (1.8826 to 1.8836 inch) (C) Maximum radius ....... 0.38 mm (0.015 inch)2 Specifications Section Recess for Exhaust Valve Seat for Naturally Aspirated Engines (A) .. 9.910 to 10.040 mm (0.3901 to 0.3952 inch) 6) . 42.420 to 42.445 mm (1.6701 to 1.6711 inch) (C) Maximum radius 0.38 mm (0.015 inch) Recess for Inlet Valve Seat for Turbocharged Engines a) 10.910 to 11.040 mm 4295 to 0.4346 inch) 6)... v-» 47.820 to 47.845 mm (1.8826 to 1.8836 inch) (C) Maximum radius ........ 0.38 mm (0.015 inch) Recess for Exhaust Valve Seat for Turbocharged Engines “ 10.910 to 11.040 mm (0.4295 to 0.4346 inch) B) nn v= 42.420 to 42.445 mm (1.8700 to 1.6710 inch) .38 mm (0.015 inch) (C) Maximum radius .. 1or495008 Cylinder Head lum distortion of the cylinder head is given SENR9778-02 Four Cylinder engine ‘tastraion 20) snoeer480 ‘The tghtoning soquonce Three Cylinder engine Table 2 Required Tools Part Nowber Part Description ary 21825607 Angle gauge 1 ‘The cylinder head bolts are two different lengths. The following information provides the proper torque for the cylinder head bolts. ‘ustration 21 ‘goror7007 ‘Tho tghtoning sequence Lubricate the threads and the underside of the head bolts with clean engine oil. Tighten the bolts in the sequence that is shown in Illustrations to the following torque. ....... 50 Nem (G7 Ib f) Tighten the bolts again to the following torque. 100 Nem (74 tb ft)‘SENR9778-02 8 Specifications Section Three Cylinder Engine © c he. 8 mS ©) : 2S) c istration 22 0908623 L ami “oror7ea8 ‘The head bolts require an additional torque turn ren procedure. The numbers (1, 3, 4) are three long Tobie 3 cylinder head bolts. All he other bolts are short bolts. 7 Saas ‘The tightening sequence is shown in the illustrations . Dimension. Te Place the angle gauge on the top of each bolt Wieth (A) 0.03 mm (0.0048 inch) head. Tighten the short bolts to the additional AMOUN, nn nnnneninenenne 225 degrees Lenath (©) 10.05 mm (0.0019 inch) Place the angle gauge on the top of each bolt Diago head. Tighten the long bolts for the additional pelea Sere event amount... vevnnevrennee 270 degrees Thickness ofthe cylinder head .. 117.950 118.05 mm ait (4.643 to 4.64/ inch) Turbocharger Minimum thickness of cylinder head .....117.20 mm (4.614 inch) Note: The maximum distortion of the cylinder head is given in table 3. Four Cylinder Engine inustration 23 prance tustraten 25 sn0891957 “Typical turbocharger (1) Actuator rod (2) Actuator (8) Turbocharger14 Specifications Section ‘SENR9778-02 (4) Tighten the nuts to the following torque. . 47 N-m (34 Ib f) (6)-Tighten the bolt to the following torque. ..... 9 N-m (80 Ib in) (6) Tighten the bolt to the following torque... 22 Nem. (16 Ib f) ‘The maximum test pressure for the waste gate 205 kPa (30 psi) ‘The movement for the rod actuator 1mm (010384 inch) Four Cylinder Engine Three Cylinder Engine Table 5 ‘The part number for | The pressure for the the turbocharger ‘waste gate 2OTAAAOS 100 & 3 kPa (14.5040 ¢ 0.4351 psi) 267AAA21 100 # 3 kPa (14,5040 # 0.4351 psi) peranaza 200 + 3 kPa (28.0080 + 0.4381 psi) Exhaust Manifold Tabled The part number for | The pressure for the the turbocharger ‘waste gate . . De7eA200 700 4 5 kPa Four Cylinder Engine (14.5040 + 0.7282 psi) 26740201 110 & § KPa (15.9544 2 0.7262 psi) 26744202 128 + 5 kPa (18.5651 + 0.7252 psi) ak 26744209 100 + 5 KPa an (14.5040 + 0.7282 psi) CY aa ames = — ) (18.5651 + 0.7252 psi) | 9) 26744215 128 + § kPa (18.5651 + 0.7282 psi) 6 4 37 2074A203 136 4 § kPa SEE aa PEER reer (19.7254 s 0.7252 psiy tustration 26 2674K228 136 + § kPa Tightening sequence (19.7254 # 0.7262 psi) Note: The exhau: ifold be aligned jote: The exhaust manifold must be aligned to persis ee a a the cylinder head. Refer to the Disassembly and ‘Assembly manual. 2674A226 100 + § KPa (14.5040 + 0.7252 psi) Tighten the exhaust manifold bolts in the sequence that is shown in illustration 26 to the following 2674K227 128 + § kPa (fe.5661 £07252 psiy torque. : 33.Nem (24 Ib A)‘SENR9778-02 Three Cylinder Engine imustration 27 ‘oo1o77009 Note: The exhaust manifold must be aligned to the cylinder head. Refer to the Disassembly and Assembly manual. Tighten the exhaust manifold bolts in the sequence that is shown illustration 27 to the following LOFQUE. vvnnnnne 33 Ne (24 Tl ft) Camshaft iustration 28 0887750 ‘Checking the end pla ofthe camshaft (1) End play of a new camshaft ..... 0.10 to 0.55 mm 104 to 0.022 inch) Maximum permissible end play of a worn camshaft (0.60 mm (0.023 inch) 15 Specifications Section ‘Mustration 29° 900976195, Typical camsnot (2) Bott Tighten the bot to the following torque... 95 Nm (70 Ib ft) (3) Camshaft thrust washer ‘Thickness of the thrust washer .. 5.49 to 5.54 mm (0.216 to 0.218 inch) Depth of the recess in the cylinder block for the thrust washer 5.54 to 5.64 mm (0.218 to 0.222 inch) Tolerance of the thrust washer in cylinder block front face... “0.184 to =0,003 mm (0.0006 to -0.0001 inch) (4) The diameters of the camshaft journals are given in the following tables. Tablo 6 1104 Diameters of Camshaft Journals ‘Standard Diameter 50.71 to 50.74 mm (1.9965 to 1.9975 inch) 50.48 to 5048 mm (1.9865 to 1.9875 inch) 710.05 to 40.08 mm (1.9866 to 1.9875 inch) ‘Camshaft Journals 1 216 Specifications Section ‘apie 7 1103 Diameters of Camshaft Journals ‘Camshaft Journals ‘Standard Diameter * 50.71 to 60.74 mm (1.9985 to 1.9975 inch) 3 50.46 to 60.48 mm (1.9865 to 1.9875 inch) 50.48 to 0.48 mm (1.9865 to 1.9875 inch) 49.95 to 49.98 mm (1.9865 to 1.9875 inch) 3 4 Maximum wear on the camshaft journals ... 0.05 mm. (0.0021 inch) ‘SENR9778-02 1. Measure the camshaft lobe height (6). 2. Measure the base circle (7). 3. Subtract the base circle that is found in Step 2 from the camshaft lobe height that is found in Step 1. The difference is the actual camshaft lobe lift. ‘Maximum permissible clearance between the actual lobe lift and the specified lobe lift of anew camshaft... (0.05 mm (0.021 inch) Camshaft Bearings Imustraion 30 ‘posas7a2 (5) Camshaft lobe litt Naturally aspirated Inlet lobe .... senone 7.382 t0 7.482 mm (0.2906 to 0.2946 inch) Exhaust lobe senna 7-404 t0 7.504 mm (0 2914 to. 0.2984 inch) Turbocharged Inlet lobe 7.031 to 7.130 mm (0.2768 to 0.2807 inch) Exhaust lobe... . 7,963 to 8.063 mm “(0.3185 to 0.3174 inch) (©) Camshaft lobe height (7) Base circle To determine the lobe lift, use the procedure that follows: ‘stration 31 sears ‘A typical four cyndor engine‘SENR9778-02 Inustraion 32 wror7o ‘three cylinder engine (1) Camshaft bearing ‘The diameter for the installed camshaft bearing seimeee 50.790 t0 50.850 mm (1.9996 to 2.0020 inch) ‘oresa00 Engine Oil Filter Spin-on Oil Filter Imustraton 33 (1) Seal Note: Lubricate the top of the seal with clean engine oil before installation. Type Full flow 7 Specifications Section Pressure to open engine oil fiter bypass valve 80 to 120 kPa (12 to 18 psi) Replaceable Element ‘mustraton 34 Noto: Lubricate the seal on the oil iter housing with clean engine oil before installation. TYPO sncnnntrnnntnnnnetneeee FUll OW Pressure to open engine oil fiter bypass. valve .. .. 190 to 170 kPa (19 to 25 psi) (1) Tighten the oil titer housing to the ot! titer base to the following torque. .......... 25 Nem (18 Ib ft) (2) Tighten the drain plug on the cil iter housing to the following torque. 12 Nem (9 Ib ft) Note: The horizontal filter as a drain plug in the filter head (8) Recess for 1/2 inch square drive foresr6 Engine Oil Pump Four Cylinder Engines with Balancer Group Number of lobes Gear-driven differential rotor Unmet FOLOF anne snes 8 Outer rotor on vee18 ‘Specifications Section SENR9778-02 3 Imustraton 35 poses248 Itustraton 37 so09es2r7 ‘The oll pump forthe balancer The end play forthe rotor (1) Clearance of the outer rotor to the (8) End play of rotor assembly body .. 0.130 to 0.24 mm (0.0080 to 0.0094 inch) Unmet FOLOF ener 0.04 10.0.1 mm, (€166%6 to 0.0043 inch) Outer POOF nen 0:04 to 0.00 mm. Imustration 35 ‘0888236 Inner rotor (2) Clearance of inner rotor to outer POOF nese 0,050 to 0.200 mm (0.0020 to 0.0079 inch) (€.0016 to 0.0043 inch) stration 38 ‘ous ‘The and cover (4) Torque for cover bolts for oil pump ..‘SENR9778-02 Imustration 39 ‘0888519 Idler gear and pump gear Note: Replace the idler gear bolt (5) and the nut for the oil pump gear (6). (8) Tighten the idler gear bolt to the following FOMQUE. es nnnne soo 26 Nem (19 Ib ft) Note: Set the engine to the TC position. Refer to Testing and Adjusting , “Finding Top Center Position for No. 1 Piston’. Install the balancer. Refer to the Disassembly and Assembly manual. install the gear for the oil pump and tighten the nut (6). (6) Tighten the nut to the following torque. ... 95 Nem ob f) ‘Tighten the bolts that hold the balancer to the cylinder. block to the following torque. .......... 54 N-m (40 Ib ft) Four Cylinder and Three Cylinder hout Balancer Group Gear-driven differential rotor Inustration 40 The oil pump 19 Specifications Section (1) Clearance of the outer rotor to the body 0.152 to 0.330 mm (€.0059 to 0.0129 inch) ‘Mustration 41 gpnsseass checking the clearance: (2) Clearance of inner rotor to outer FOOT oo sonnnnnnn 0.040 to 0.127 mm (0.001 to 0.0050 inch) ‘Mustration 42 00990788 Checking the end play (2) End play of rotor assembly Unmet FOLOF nner 0.038 t0 0.089 mm (€.0014 to 0.0035 inch) Outer rotor nn 0.025 to 0.076 mm (€.0010 to 0.0020 inoh) Tighten the bolts that hold the front cover of the oil pump assembly to the following torque. ...... 26 N'm (19 Ib f) Engine Oil Pressure The minimum oil pressure at the maximum engine speed and at normal operating temperature is the following value. 200 kPa (43 psi)20 Specifications Section Engine Oil Bypass Valve Installed in the Oil Pump ustation 43 00918885 Imustration 48 wooaztsrt Rober valve and spring (1) Tighten the plug for the relief valve to the following torque. sooese 35 Nem (26 Ib ft) (2) Plunger Diameter of the plunger ..... 19. 166 to 19.211 mm. (0.7554 to 0.7583 inch) Clearance of plunger in bore .. 0.039 t0.0.114 mm. (0.0015 to 0.0045 inch) Installed in the Balancer 1104 engines only SENR9778-02 ‘mustravon 46 sposasa7s “Tho role valve forthe balancor (1) Tighten the plug for the relief valve to the following torque. ... . 35 Nem (26 Ib ft) (2) Plunger Diameter of the plunger ...... 14.46 to 14.48 mm (0.5692 to 0.5700 inch) Clearance of the plunger in the bore ... 0.04 to 0.08 mm (0.0015 to 0.0031 inch)SENR9778-02 Engine Oil Pan Front sealant Iustration 47 ‘Applying sealant (1) Apply 1861108 Powerpart silicone rubber sealant to the eylinder block and to the timing case. Note: Apply a sealant bead ot 2.b mm (U.13/8 inch) that is shown in illustration 47. Rear sealant Note: Install the rear oll seal before sealant is applied to the bridge. Iustation 48 poss0255 ‘Apalying sealant (2) Apply 1861108 Powerpart silicone rubber sealant to the bridge. The sealant must not protrude more than 5 mm (0.1969 inch) above the bridge. Note: The cil pan must be installed within 10 minutes of applying the sealant. tustraton 40 so09e0252 ‘Typleat ot! pan (3) Tighten the four front bolts to the following LOMQUE. rssnnnnnnnnnnnnnnn 22 NeM (16 Ib A) (4) Tighten the remaining bolts to the following NOMQUE ree 22. Nem (16 Ib ft)22 Specifications Section The cast iron iastration 60 o0asa245 “Tho cast on oll pan Note: The rear face of the cast iron oil pan (5) must be aligned to the rear face of the cylinder block. (6) The maximum allowed value of the rear face misalignment. (0.1 mm (0.0039 inch ) ) Bolt Tighten the front four bolts. Refer to illustration 449. Tighten the remaining bolts and the nuts that fasten the engine oil pan to the cylinder block to. the following torque. ............ 22. Nem (16 Ib ft) Note: The sealant is applied to new bolts. In order to reuse the bolts, apply 21820117 Powerpart Uneauluck ard nulloch Wy Ue frst nce Uneads of the used bolts. Note: The engine may be equipped with an oil drain plug or the engine may be equipped with a drain valve, (7) Drain plug Tighten the drain plug for the engine oil pan to the following torque. ..... 34. 5 Nem (25 + 4 Ib ft) SENR9778-02 ‘Mustration 51 00990677 The drain valve (8) Drain valve Tighten the drain valve into the adapter to the following torque. ......... 34 5 Nom (25 £4 Ib ft) (8) Adapter Tighten the adapter into the engine oil pan to the following torque. 34 £5Nm (25 £4 Ib f) vse Crankcase Breather ‘Mustration 52. 900926199 Breather vate (1) Plastic cover (2) Cover plateSENR9778-02 (3) Screws, Tighten the screws for the cover plate with a plastic valve mechanism cover to the following torque. . 1.3. Nem (11.5 Ib in) Tighten the ‘cover plate with a metal valve mechanism cover to the following torque. .. 1.8 Nem (16 Ib in) (4) Diaphragm (6) Cap (6) Spring Imustration 53 (7) O-ting Note: Apply 21820221 Powerpart red rubber grease to the O-ring before installing the breather pipe in the valve mechanism cover. (€) Tighten the bolts that secure the breather pipe to the cylinder head to the following torque. ... 9 N:m (60 Ib in) Engine model DK and DJ Note: These three cylinder engines do not have a breather valve in the valve mechanism cover. ‘Mustraton 54 ovate? (1 Plastic cover (2) Screw (3) Cover plate (4) Seat (2) Tighten the screws for the cover plate with a plastic valve mechanism cover te the following HOMQUE. eee 4.3.Nem (11.5 Ib In) rora2s6 Water Temperature Regulator and Housing Tighten the bolts (not shown) that fasten the housing to the following torque... 22Nm (16 1b) Inustraton 55 sooveTzs4 ning Note: Apply 21820221 Powerpart red rubber grease to the O-ring (1) in order to install the thermostat housing.24 Specifications Section ‘SENR9778-02 Water Temperature Regulator om a2 ¥ Cea Imustration 55 ‘sposeer28 ‘A typleal wator tomporatur regulator Opening temperature eevee 79° to 84°C (174° to 151 °F) Full opcning temperature 93°C (190 °F) Minimum stroke at full open temperature ...... 10 mm. (0.3937 inch) Water Pump Inustravon 87 sposts854 Tightening sequence Note: Apply 21820117 Powerpart threadiock rnutlock to the first three threads of the bolts before installation. Tighten the nine bolts that secure the water pump to the front housing in the numerical sequence that is shown to the following torque. 22 Nem (16 Ib ft) Note: Refer to the Disassembly and Assembly ‘manual in order to service the water pump. Cylinder Block Four Cylinder Engine Iustraton 58 sooenarea Cylinder block (1) Cylinder block (2) Cylinder bore 105.000 to 105.025 mm (4.1338 to 4.1348 inch) The first oversize bore diameter 105.5 to 105.525 mm (4.1535 to 4.1545 inch) The second oversize bore diameter... .. 108,000 to 106.025 mm (4.1732 to 4.1742 inch) ‘The maximum permissible wear for the cylinder bore 0100.15 mm (0 to 0.0059 inch) (3) Camshaft bearings for the four cylinder engine Diameter of the bore in the cylinder block for the number 1 camshaft BOAT nnn 85-563 to 85.593 mm (2.1875 to 2.1887 inch)SENR9778-02 Diameter of the bore in the cylinder block for the number 2 camshaft joura .. . 50.546 to 50.597 mm (1.8900 to 1.9920 inch) Diameter of the bore in the cylinder block for the number 3 camshaft journal... 50.038 to 50.089 mm (1.9700 to 1.9720 inch) (4) Main bearings for the four cylinder engine Bore in the cylinder block for the main bearings .. 80.416 to 80.442 mm 1660 to 3.1670 inch) (6) Main bearing cap bolts for the four cylinder engine Use the following procedure in order to install the main bearing cap bolts: 41. Apply clean engine oil to the threads of the main bearing cap bolts, 2. Put the main bearing caps in the correct position ‘hat is indicated by a number on the top of the main bearing cap. Install the main bearing caps ‘with the locating tabs in correct alignment with the recess in the cylinder block. 3. Evenly tighten the main bearing cap bolts. ‘Torque for the main bearing cap bolts. ... 245 Nm (180 Ib f) Imustraion 50 Use the following procedure in order to install the Allen head bolts for the bridge. Note: Install the rear seal before sealant is applied. 1. Use a straight edge in order to ensure that the bridge is aligned with the rear face of the cylinder block. 2. Tighten the Allen head bolts (6) for the bridge. ‘Toree for the Allen head haite 16N-m (42th 25 Specifications Section 3. When the bridge is installed on the cylinder block, apply 21826038 POWERPART Silicon Adhesive into groove (7) at each end of the bridge. Apply the sealant into the groove until the sealant is forced through the bottom end of the groove in the bridge. ‘Total height of the cylinder block between the top and the bottom faces. 441.173 to 441.274 mm (17.3689 to 17.3729 inch) Three Cylinder Engine ‘ustravon 60 secrets. (8) Cylinder block (2) Cylinder bore 105,000 to 105.025 mm (4.1338 to 4.1348 inch) The first oversize bore diameter ....... eee 105.5 to 105.525 mm (4.1535 to 4.1545 inch) ‘The second oversize bore diameter ....... vse 106.000 to 106.025 mm (4.1732 to 4.1742 inch) ‘The maximum permissible wear for the cylinder bore sss. 00 0.18 mm (0 to 0.0059 inch) (10) Camshaft bearings for the four cylinder engine Diameter of the bore in the cylinder block for the number 1 camshaft bearing 35.563 to 55.583 mm (2.1875 to 2.1887 inch) Diameter of the bore in the cylinder block for the number 2 camshaft joumal 50.546 to 50.597 mm26 Specifications Section Diameter of the bore in the cylinder block for the number 3 camshaft joural .. 50.546 to 50.597 mm (1.8900 to 1.9920 inch) Diameter of the bore in the cylinder block for the number 4 camshaft joumal .. ‘50.038 to 50.089 mm (1.9700 to 1.9720 inch) (11) Main bearings for the three cylinder engine Bore in the cylinder block for the main bearings .. 80.416 to 80.442 mm (2.1660 to 3.1670 inch) (12) Main bearing cap bolts for the four cylinder and three cylinder engines Use the following procedure in order to install the main bearing cap bolts: 41. Apply clean engine oil to the threads of the main bearing cap bolts, 2. Put the main bearing caps in the correct position ‘hat is indicated by a number on the top of the main bearing cap. Install the main bearing caps ‘with the locating tabs in correct alignment with the recess in the cylinder block. 3. Evenly tighten the main bearing cap bolts. Torque for the main bearing cap bolts... 245. Nm (180 Ib #) Inustration 61 ‘prorenee Use the following procedure in order to install the Allen head bolts for the bridge. Note: Install the rear seal before sealant is applied. 1. Use a straight edge in order to ensure that the bridge is aligned with the rear face of the cylinder block. ‘SENR9778-02 2. Tighten the Allen head bolts (13) for the bridge. Torque for the Allen head bolts .. 16 Nem (12 Ib ft) 3. When the bridge is installed on the cylinder block, apply 21826038 POWERPART Silicon Adhesive into groove (14) at each end of the bridge. Apply the sealant into the groove until the sealant is forced through the bottom end of the groove in the bridge, ‘Total height of the cylinder block between the top and the bottom faces. 441.173 to 441.274 mm (17.3689 to 17.3729 inch) ‘or9s5s20 Crankshaft ‘Mustration 62 gpnveaats ‘The crankshaft forthe four cylinder engine (1) Crankshaft for the four cylinder engine ‘The maximum end play of the crankshaft ..0.51 mm (0.0201 inch) (2) Thrust washers Standard thickness . 2.26 to 2.31 mm (0.088'to 0.091 inch)SENR9778-02 2 Specifications Section Oversize thickness 2.45 to 2.50 mm (0.097 to 0.098 inch) (3) The crankshaft gear Maximum permissible temperature of the gear for installation on the crankshaft... 180 °C (356 °F) Note: The timing mark is toward the outside of the crankshaft when the gear is installed on the crankshaft. Note: All new turbocharged engines and turbocharged aftercooled engines have crankshafts that are nitrocarburised. The crankshaft can also be nitrided for 20 hours, if the nitrocarburised process is not available. After a crankshaft has been machined, the crankshaft must be rehardened. Inspect the crankshaft for cracks before machining and after machining. Naturally aspirated engines: have induction hardened crankshaffs. 8 8 8 4 3 8 <_ <> ustation 63 OTS The 1104 engine crankshan Note: Refer to illustration 63 in order to use table 8. ‘The four cylinder engine,28 Specifications Section Table & ‘SENR9778-02 The undersize diameter cf the Crankshaft Journals NUMBER (0.25 mm (0.010 inch) 0.51 mm (0.020 inch) (0.76 mm (0.030 inch) 4 75,908 mm (2.9885 inch) to | 75.649 mm (2.9783 inch) to. | 75.399 mm (2.9685 inch) to 75.930 mm (2.9894 inch) _| 75.870 mm (2.9781 inch) _| 75.420 mm (2.9693 inch) {68.220 mm (2.4890 inch) to. | 62.960 mm (2.4787 inch) to | 62.708 mm (2.4688 inch) to & 63.240 mm (2.4898 inch) | 62.982 mm (2.4796 inch) _| 62.728 mm (2.4698 inch) 38.47 mm x (1.5538 inch)maximum Ne ae 37.44 mm 4 (1.4740 inch) maximum NA NA 44.68 mom 5 (1.7894 inch)maximum NA NA 40.55 mm é (4.5865 inch) maximum NA NA 7 ‘Donet machine this diameter. NA NA ‘2.68 mm (0.1449 inch) to & 3.96 mm (0.1858 inch) NA NA Refer to table 9 for the maximum run out of the ‘crankshaft journals. ‘The maximum difference in value between one crankshaft journal and the next crankshaft journal (9.10 mm (0 ANA inch) Table 9 Journal Excessive run out o Mounting @ 0.08 mm (0.0081 ineh) & 0.48 mm (0.0069 inch) 4) 0.08 mm (0.0081 inch) © Mounting Refer to the Specifications Module, “Connecting Rod Bearing Journal” topic for more information on the ‘connecting rod bearing journals and connecting rod bearings. Refer to the Specifications Module, “Main Bearing Journal" topic for information on the main bearing journals and for information on the main bearings.‘SENR9778-02 29 Specifications Section 3 3 7 r? | \ 1 Keo fa 1 2 8 6 tmstaton 64 oovorrrar “The crankshat forthe tree eylnder engine ‘The crankshaft for the three Cylinder engine30 Specifications Section Table 10 The undersize diameter cf the Crankshaft Journals ‘SENR9778-02 NUMBER 0.25 mm (0.010 neh) | 051 mm (0.020 inch) ‘0.76 mm (0.080 inch) - 75.926 mm (2.9892 inch) to | 76672 mm (2.9782 inch) to | 75.418 mm (2.9602 inch) to 75.905 mm (2.9684 inch) | 75.851 mm (2.8784 ineh) —_| 75.387 mm (2.9684 inch) 163.286 mm (2.4896 Inch) to | 62.962 mm (2.4786 inch) to | €2.728 mm (2.4698 inch) to Z 63.216 mm (2.4888 inch) 62.962 mm (2.4788 inch) 62.708 mm (2.4688 inch) 3874 mm 3 (1.5646 inch)maximum tA ts 44.58. mm 4 (1.7591 inch)maximum NA NA 40.551 mm 5 (1.5965 inch)maximum NIA NIA 198.17 mm (62428 inch) Do é not machine this diameter. NA NIA 3.68 mm (0.1449 inch) to 7 3.98 mm (0.1559 inch) NA NA Refer to table 11 for the maximum run out of the pisses crankshaft journals. i Crankshaft Seals ‘The maximum difference in value between one crankshaft journal and the next crankshaft journal 0.10 mm (0.0039 inch) Table 11 Journal Excessive run out a Mounting Dia 2 (0.051 mm (0.0020 inch) @ (0.051 mm (0.0020 inch) @ Mounting Dia Refer to the Specifications Module, “Connecting Rod Bearing Jounal” topic for more information on the ‘connecting rod bearing journals and connecting rod bearings. Refer to the Specifications Module, “Main Bearing Journal" topic for information on the main bearing journals and for information on the main bearings. tustration 65 (1) Crankshaft (2) Plastic sleeve (8) Crankshaft seal (4) Alignment tool‘SENR9778-02 34 Specifications Section Inustration 65 soar (5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the sequence that is shown in Illustration 66 to the following torque. 22.Nem (16 Ib ft) Remove the alignment tool. Tighten bolls 8 and 9 in the sequence thal is shown in Ilustration 86 to the following torque. ....... 22 N-m (16 Ib f) Connecting Rod Bearing Journal Refer to the Specifications Module, “Crankshaft” topic for information on the undersize crankshaft journals. ‘The original size of the connecting rod bearing journal ... 63.47 to 63.49 mm (2.4888 to 2.4996 inch) Maximum permissible wear of the connecting rod. bearing journals 0.04 mm (0.0016 inch) Width of the connecting rod bearing journals ..... 40.35 to 40.42 mm (1.589 to 1.581 inch) Radius of the fillet of the connecting rod bearing joumals 3.68 to 3.96 mm (0.145 to 0.156 inch) ‘Surface finish of connecting rod bearing journals and radii . Ra 0.4 microns (16 winch) Main Bearing Journal Refer to the Specifications module, “Crankshaft” topic for information on the undersize main bearing journals, and information on the width of main bearing journals. The original size of the main bearing JOUR «er rrrrrrns 76.159 t0 76.180 mm (2.9984 to 2.9992 inch) ‘Maximum permissible wear of the main bearing joumals .040 mm (0.0016 inch) Radius of the filet of the main bearing journals .... 3.68 to 3.69 mm (0.1448 to 0.1452 inch) ‘Surface finish of bearing journals, crank pins and. radi (0.4 microns (16 y inches) The shell for the main bearings The shells for the main bearings are available for remachined journals which have the following undersize dimensions. Undersize bearing shell ... 0.25 mm (0.010 inch) Undersize bearing shell ... 0.51 mm (0.020 inch) Undersize bearing shell ... 0.75 mm (0.030 inch) Thickness at center of the shells ...2.083 to 2.089 mm (0.0820 to 0.0823 inch) Width of the main bearing shells .. 31.62 to 31.88 mm (1.244 to 1.255 inch) Clearance between the bearing shell and the main bearing JOUMNAIS «ene 0.087 to 0.117 mm (€.0022 to 0.0046 inch)32 Specifications Section Connecting Rod Mustation 67 ‘900807738 The mating surfaces of the connecting rod are produced by hyaraulleally fracturing the forged ‘connecting rod (1) Tighten the torx screws for the connecting rod to the following torque... 18 Nem (13 Ib ft) Tighten the torx screws for the connecting rod again to the following torque. ._ 70.N-m (52 Ib ft) Tighten the torx screws for the connecting rod for an additional 120 degrees. The torx screws for the connecting rod (1) must be replaced after this procedure. Note: Always tighten the connecting rod cap to the ‘connecting rod, when the assembly is out of the engine. Tighten the assembly to the following torque 20m (14 Ib ft). (2) The bearing shell for the connecting rod SENR9778-02 ‘Mustration 68 sposessed ‘Alignment of the bearing she Note: The bearing shell for the connecting rod ‘must be aligned equally from both ends of the connecting rod. Refer to (A) in figure 68. Refer to the Disassembly and assembly manual for information on the alignment tool Tabi 12 Bearing Width for he | 34.8210 91.88 mm Connecting Rod (1.245 to 1.255 inch) Bearing Wath forthe | 34.56 to 31.88 mm Conneeting Rod Cap__| (128050 1.255 neh) Thickness of Connecting | — 4 255 w 1.849 mm Rod Bearing a the Center (0.0723 to 0.0728 inch) Thickness of Connecting | 4 655 w 1.842 mm Rod Bearing for the Cap | (5729 0 0.0725 rch) at the Center 10.030 to 0.081 mm (0.0012 to 0.0032 inch) Bearing Clearance abla 19 Undersized Connecting Rod Bearing (0.25 mm (0.010 inch) 0.51 mm (0.020 inch) (0.76 mm (0.030 inch)‘SENR9778-02 ‘mustration 69 0se7Ts4 (8) Diameter of the parent bore for the piston Bin... 43,01 to 43.04 mm (1.693 to 1.694 inch) (4) Distance between the parent bores wn 219,05 to 219.10 mm (8.624 to 8.626 inch) (6) Diameter for the parent bore for the connecting rod bearing sooeneesee 67-24 t0 67.22 mm (2.6460 to 2.6465 inch) 33 Specifications Section rable 14 Length Grades for Connecting Rods GradeLerer| Color code | __Length (M) 7 ea | 195728 t 165.761 mm (6.5247 to 6.5260 inch) 185.662 to 165715 mm fi Orange | (65229 196.5242 inch) 185.637 to 165.570 mm Hl Wis: (6.5211 to 6.5224 inch) 165.501 to 165.624 mm 4 Green | (6.5193 to 6.5206 inch) 185.545 to 165.578 mm kK Purple | (6.5175 to 6.5188 inch) 185.499 to 165.592 mm t Blue (6.5157 to 6.4961 inch) Piston and Rings iustation 70 990978086 ‘Connesting rods are color coded. The color code is a reference for the lenath (Y) of the connecting rod. Refer to table 14 for the different lengths of, ‘connecting rods. ‘stration 71 Atypical example ofa piston and rings (1) Top compression ring Naturally Aspirated ‘The shape of the top compression ring .. Rectangular with a barrel face ‘Width of the top compression Ting ....... 2.475 to 2.49 mm (0.097 to 0.098 inch) Clearance between the top compression ring and 0.09 to.15mm (0.0035 to 0.0059 inch) seven 0,30 10 0.55 mam (@.01%8 to 0.0216 inch) ‘The shape of the top compression fing .. Keystone with a barrel face Wicith oF the tan comnreccion rind ‘tanerad34 Specifications Section 0.30 to 0.55 mm (0.0118 to 0.0216 inch) Ring gap Note: When you install a new top compression ring, make sure that the word "TOP" is facing the top of the piston. New top piston rings have a red identification ‘mark which must be on the left of the ring end gap when the top piston ring is installed on an upright piston. (2) Intermediate compression ring ‘The shape of the intermediate compression ring .. .. Internal step in the bottom edge with a tapered face Width of intermediate compression fing ........ 2.47 to 2.49 mm (0.097 to 0.098 inch) Clearance between the intermediate compression ring and the piston groove ....... 0.05 to 0.09 mm. (0.002 to 0.003 inch) Ring gap... sneecnete 0.70 t0 0.95 mam (0.0275 to 0.0374 inch) Note: When you install a new intermediate ‘compression ring, make sure that the word “TOP” is facing the top of the piston. New intermediate rings have a green identification mark which must be on Une fe Ue sin etl yas wet Une Lap installed on an upright piston. (8) Oil control ring Shape of oil control ring ‘two-piece coil that is spring loaded Width of oil control ring .......... 3.47 to 3.49 mm. (0.1366 to 0.1374 inch) Clearance between the oil control ring and the groove in the piston . 0.03 to 0.07 mm. (0.0611 to 0.0027 inch) . 0.30 to 0.55 mm (0.0148 to 0.0216 inch) Ring gap Note: A pin is used in order to hold both ends of the ‘spring of the oil control ring in position. The ends of Une spting of the oll eonol ring must be installed opposite the end gap of the oil control ring. Note: Ensure that the ring end gaps of the piston rings are spaced 120 degrees from each other. Piston Note: An arrow which is marked on the piston crown ‘must be toward the front of the engine. ‘The combustion bow! re-entrant angle for the turbocharged engine 80 degrees ‘SENR9778-02 ‘The combustion bow re-entrant angle for the naturally aspirated engine 70 degrees Piston height above cylinder block .. 0.21 to 0.35 mm (0.008 to 0.014 inch) Wiath of top groove in piston for the naturally aspirated engine ... 2.58 to 2.60 mm (0.1016 to 0.1024 inch) Width of top groove in piston for the turbocharged OAQING oc ceereneenetneeeeeeeerees Tapered Width of second groove in piston ... 2.54 to 2.66 mm (0.1000 to 0.1008 inch) Width of third groove in piston ...... 3.52 to 3.54 mm (6.1386 to 0.1384 inch) Piston pin Diameter of a new piston pin 39,694 to 39.700 mm (1.5628 to 1.5630 inch) Diameter of the bore for the piston pin 39.703 to 39.709 mm (1.5631 to 1.5633 inch) Piston Cooling Jet Noto: The three cylinder naturally aspirated engine ‘may have installed piston cooling jets as an option. | Iustration 72 (1) Instatod piston coating ots ‘The spring loaded valve must move freely. Tighten the bolt to the following torque. ....... 9 Nem (7 Ib ft)‘SENR9778-02 Piston Cooling Jet Alignment Iustration 73 (2) Piston cooing jot (G)Rod (4) Cylinder block Use the following procedure in order to check the alignment of the piston cooling jet. 1. Insert rod (3) into the end of the piston cooling jet (2). Rod (3) has a diameter of 1.70 mm (0.067 inch), Rod (3) must protrude out of the top of the cylinder block. 2. Dimension (A) is 5 25 mm (2.4757 inch) andl dimension (B) is 14 mm (0.5512 inch). Dimension (A) and dimension (B) are tangent to the cylinder bore (4). 3. The position of the rod (3) must be within dimension (C). Dimension (C) is 14 mm (0.5512 inch). 1or957009 Front Housing and Covers ‘The front housing must be aligned to the cylinder block face... _. + 0.05 to minus 0.05 mm. (+ 0.0020 to minus 0.0020 inch ) ‘stration 74 0996669 Alignment (1) Tighten the bolts that fasten the front cover to the front housing to the following torque. ..... 22 N-m (16 Ib f) 0098672 ‘Mustration 75 Front cover (2) Tighten the bolts that fasten the water pump to the 22.N-m Note: Refer to Specifications, “Water Pump” for the correct bolt tightening sequence for the water pump.36 Specifications Section ‘SENR9778-02 Gear Group (Front) The 1104 mechanical engines use two types of fuel injection pumps. The fuel injection pump can be either a Delphi 210 fuel injection pump or a Bosch EPVE fuel injection pump. iustration 78 Gear tain (1) Fuel injection pump drive gear Tighten the nut to the following torque. ..24 N-m (18 Ib f) Release the lock on the fuel injection pump shaft. ‘Torque the nut to the following torque. .... 90 N-m (66 Ib f) Number of teeth 68 Note: Refer to the Specifications Module, "Fuel injection pump” for the locking torque for the fuel injection pump shaft. (2) Camshaft gear Tighten the bolt for the camshaft gear to the following torque. een 95 Nem (70 Ib ft) Bore diameter of the camshaft gear 34.93 to 34.95 mm (1.3750 to 1.3760 inch) Outside diameter of the camshaft bub .. 34.90 to 34.92 mm (1.3741 to 1.3747 inch) Clearance between the camshaft gear and the camshaft hub 0.003 to 0.048 mm (€.0001 to 0.0019 inch) Number of teeth seen O8 (2) Idler gear and hub Tighten the bolts for the idler gear to the following torque. .. 44 Nem (33 Ib ft) Bore diameter of the idler gear ones 57-14 to 87.18 mm (2.2495 to 2.2512 inch) Bore diameter of the idler gear with roller DEALINGS nner 72.35 t0 72.38 mm (2.8484 to 2.8488 inch) Width of idler gear and split bearing ASSEMDIY cree 30.14 f0 30.16 mm (1.186 to 1.187 inch) Inside diameter of idler gear bearings with flanges ._ 50.78 to 50.80 mm (1.999 to 2.000 inch) Outside diameter of idler gear hub ...50.70 to 50.74 mm (7.9961 to 1.9976 inch) Outside diameter of idler gear hub with roller bearings. 49.975 to 49,988 mm (1.9675 to 1.9680 inch) Clearance of idler goar bearing on hub .... 0.04 to 0.10 mm (0.0016 to 0.0039 inch) Idler gear end play... 0.10 to 0.20 mm (0.004 to 0.008 inch) Idler gear end play with roller BeAFIAGS enn 0.10 t0 0.75 mam, (€.0039 to 0.0295 inch) Maximum permissible end play ......... 0.38. mm (0.016 inch) Number of teeth ‘wustration 77 Tho gear train forte oll pump (4) Crankshaft gearSENR9778-02 Bore diameter of crankshaft gear ‘47.625 to 47.650 mm (1.8750 to 1.8760 inch) Outside diameter of crankshaft hub 47.625 to 47.645 mm (1.8750 to 1.8758 inch) Clearance of gear on crankshaft 0.020 to +0.020 mm (0.0008 to +0.0008 inch) Number of teeth ... 34 (5) Oil pump idler gear Inside diameter of oil pump idler gear bearing 16,012 to 16.038 mm (0.6304 to 0.6314 inch) Outside diameter of oll pump idler gear shaft... nee 18,966 to 15.984 mm. (0.6286 to 0.6293 inch) Clearance of oll pump idler gear bearing on shaft vnnens 0,028 to 0.072 mam (0.0011 to 0.0028 inch) End play of the oil pump idler GAP an svwene 0,050 to 0.275 mm. (0.0019 to 0.0108 inch) (6) O1| pump gear ‘The number of teeth on the oil pump gear ..... 17 Backlash values Backlash between the idler gear (5) and the oil pump drive gear (6) 0.046 to. 0.106 mm (0.0018 to 0.0041 inch) Backlash between the oil pump idler gear (5) and the crankshaft gear (4) ....... 0.095 to 0.160 mm (0.0037 to 0.0083 inch) Backtash between the idler gear (3) and the crankshaft gear (4) . 0,064 to 0.124 mm. (0.0025 to 0.0049 inch) Backlash between the camshaft gear (2) and the idler gear (3) vanes 0.052 t0, 0.107 men (0.0020 to 0.0042 inch) Backlash between the fuel injection pump gear (1) and the idler gear (3) ..... 0.054 to 0.109 mm. (0.0021 to 0.0043 inch) Backlash between the water pump gear (not shown) and the fuel injection pump gear (1) ... 0.073 to 0.133 mm (0.0028 to 0.0052 inch) Backlash between the power take-off drive ( if equipped) and the idler gear (3) ....0.112 to 0.172 mm (0.0044 to 0.0068 inch) 37 Specifications Section Engines that have a Balancer ‘mustravon 72 s09sKons Balancer gears (7) Idler gear for the oil pump that has a balancer The number of teeth on the gear The bore diameter of the idler GEAE neenrineenene STAGT 0 37.212 mm (1.4644 to 1.4650 inch) The hub diameter for the idler gear 37.182 to 37.162 mm (1.4627 to 1.4631 inch) ‘The end play for the idler gear . 0.12 to 0.27 mm (0.0047 to'0.0106 inch) 44 (8) Gear for the oil pump that has a balancer ‘The number of teeth on the gear .o..csessee 17 Backlash between the oil pup gear (8) and the idler gear (7) ... 0.097 to 0.17 mm (0.0038 to 0.0067 inch)38 Specifications Section Flywheel Mustration 70 rar ‘Standard tywheot (1) Flywheel ring gear Heat the fywhee ing gear to the flowing temperature, 250°C (480 °F) Note: Do not use an oxyacetylene torch to heat the flywheel ring gear. (2) Flywheel (3) Bolt Tighten the flywheel bolts to the followin: torqui Non-standard flywheel Note: A special flywheel is aligned to a dowel on the ‘crankshaft. ‘SENRO778-02 Flywheel Housing Four cylinder ‘ustraton 80 ease (1) Bott Tighten the bolts for the cast iron flywheel housing to the following torque: M1088" . . 44.N-m 33 1b) 63 N-m (47 Ib ft) 75 Nem (55 Ib ®) 115 Nem (85 bf) Three cylinder The three cylinder engine is equipped with a back plate. Crankshaft Pulley © | Re ‘stration 81 ee A standard ploySENR9778-02 39 Specifications Section Note: Lubricate the threads of the bolts with clean’ ‘engine oll before installation. (1) Tighten the three bolts for the crankshaft pulley to the following torque. 115 Nem (85 Ib ft) Note: Recheck the torque of the bolts (1) twice. (2) Thrust block (3) Crankshaft pulley Non-standard pulley istration oases (Mark (2) Alonmont mark Note: The marks (1 and 2) on the pulley must be vertical when the pulley is installed on the engine. Number one piston of the engine must be at top dead center. Fan Drive Mustration 83 Tae ‘A typical fan dive (1) Tighten the bolts for the fan to the following POGUE. oesessensesin . 22. Nem (16 Ib ft) Tighten the bolts that secure the fan drive pulley to the hub to the following torque (not shown). .. 22 Nm (16 Ib ft) Fan drive housing Tighten the bolts that secure the fan drive housing to the cylinder head to the following torque (not shown). .. 44 Nem (32 Ib f) Bearing bore for the housing .. 61.966 to 62,005 mm (2.4404 to 2.4411 inch) .. 81,987 to 62,000 mm (2.4404 to 2.4409 inch) Outer bearing diameter... Interference fit for the bearing . 0.014 to minus 0.018 mm (0.0006 to minus 0.0007 inch) ‘The outer diameter of the shaft .. 25.002 to 25.011 mm (0.9843 to 0.9847 inch) ‘Maximum permissible end play of the shaft ..0.20mm (0.0079 inch) ‘ovras290 Engine Lifting Bracket All engines are equipped with two engine lifting brackets. Tighten the two bolts on each engine lifting bracket to the following torque. .. 44 N-m (32 Ib ft)40 Specifications Section Alternator 12 Volt and 24 Volt Alternator Imnstration Ra ‘pnssssei ‘Atypical allomator (1) Tighten terminal nut “W" to the following torque. 1. 2.Nem (17 Ib in) (2) Tighten terminal nut “D+” to the following torque. ...... 4.3 Nm (28 Ib in) (8) Tighten terminal nut “B+" to the following torque. 4.3 Nem (38 Ib in) Tighten the pulley nut (not shown) to the following torque... 80 N-m (59 ib ft) Alignment of the alternator pulley to the crankshaft PUlleY nnn ++ 2.4mm (+ 0.0945 inch) Rotation elonlowise Polarity Negative earth V-Belt Note: The V-belt must be checked by a gauge. Refer to the Testing and Adjusting, "V-Belt-Test’ for the correct type of gauge in order to check the V-belt. V-belt tension ... snnenenes 535 N (120 Ib) SENR9778-02SENR9778-02 41 Specifications Section Starter Motor 24 Volt Starter Motor a, a c L s—fi, ‘Tho 24 vot starter motor which shows the electrical connections (1) Tighten the negative terminal nut to the folowing torque. . 15N-m (11 Ib f) (2) Tighten the positive terminal nut to the following torque. .... vennene 21 Ne (15 Ib) (8) Tighten the solenoid terminal to the following torque. 3.5 N-m (31 Ib in) Rated voltage .. Pullin voltage .. vo 24 volts 16 volts42 Specifications Section 12 Volt Starter Motor SENR9778-02 Iustation 85 ‘Tho 12 vot starter motor which shows the electrical connections (1) Tighten the solenoid terminal to the following torque. 8 .N-m (70 Ib in) 2) Tighten the positive terminal nut ta the following torque. 6 N-m (53 Ib in) (8) Tighten the negative terminal nut to the following torque. ... cesses 8 NAR (70 10 iM) Rated voltage ......... soosestmnssuensennsseneernee 12 VORS: Pull in voltage 8 volts voaaeuoa Glow Plugs ~, 3 Itustration 87 a Typical example (1) Tighten the glow plugs (3) in the cylinder head to the following torque. 15.Nem (11 Ib f) Tighten the nuts (2) for the bus bar (1) that is installed on top of the he glow plugs to the following torque. cee 2 Nm (18 19 in) Voltage . 12 oF 24 volts Note: Glow plugs are not installed on all engines. Engines that do not have glow plugs are installed with threaded plugs.SENR9778-02 43 Index Section Index A Flywheel .......... 38 Non-standard fiywheel.. 38 Alternator. 40 Flywheel Housing .... 38 12 Volt and 24 Volt Alternator 40 Four cylinder .. 38 V-Belt 40 Three cylinder .. 38 Front Housing and Covers. 35 Fuel Injection Lines. 5 c Fuel Injection Pump (Gosch EPVE for the 1104 engines only) ..... 6 Camshaft .......... cesscceeceeneeneee seneeee 15, Fuel Injection Pump (Delphi DP210 DPA and DPG fuel injection pumps)... 5 Delphi DP210..- ar Connecting Rod Bearing Journal...... Delphi DPA.. 6 ‘Crankcase Breather.. Delphi DPG. 6 Engine model DK an Fuel Injection Pump (Delphi STP) 7 Crankshaft _..._. Fuel Injectors............ 8 ‘Crankshaft Pulley Fuel Transfer Pump. 8 ‘Non-standard pulley. 39 Crankshaft Seals EZ go Cylinder Block. EE 4 6 Four Cylinder Engine... 24 Three Cylinder Engine Gear Group (Front)........... Cylinder Head... Engines that have a Balancer. Four Cylinder engins Glow Plugs oo... Four Cylinder Engine 2 Three Cylinder engine................... 12 Three Cylinder Engine 13, I Cylinder Head Valves ... 10 Three Cylinder Engine Engine Lifting Bracket. Engine Oil Bypass Valv@ Installed in the Balancer... Installed in the Oil Pump Engine Oil Filter nn Replaceable Element... Spin-on Oil Filter vn Four Cylinder Engines with Balancer Group...... 17 Exhaust Manifold... essen “ Four Cylinder Engine... Three Cylinder Engine F Fan Drive... Fan drive housing Important Safety Information ‘Main Bearing Journal... The shell for the main bearings. P Piston and kings: $3 Piston. 34 Piston Cooling Jet... 234 Piston Cooling Jet Alignment. 35, R Rocker Shaft. senses @ s 4Starter Motor. 44 12 Volt Starter Motor. 42 24 Volt Starter Motor ‘ 4 T Table of Contents. Turbocharger: i Four Cylinder Engine 14 Three Cylinder Engine 4 v Valve Mechanism Cover. 10 The Cover for the Four Cylinder Engine 10 ‘The Cover for the Three Cylinder Engine. 10 w Water Pump, - Water Temperature Regulator and Housing 23 Water Temperature Regulator. 24 (©2004 Perkins Engines Company LimitedPerkins Coser 204 Systems Operation Testing and Adjusting 1103 and 1104C EnginesImportant Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can offen be avoided by recognizing potentially hazardous situations before an accident occurs. A person must 2¢ alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. if these hazard wamings are not heeded. bodily injury or death could occur to you or to other persons. ‘The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word" such as “DANGER’, ‘WARNING’ or “CAUTION”. The Safety Alert ‘WARNING’ label is shown below. ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the warning explains the hazard and can be either written or pictorially presented. (Operations that may cause product damage are identified by “NOTICE” labels on the product and in ‘this publication. Perkins cannot anticipate every:possible circumstance that might Involve ‘potential hazard. ‘The warnings in this publication and on the product are, therefore, not all inclusive. Ifa tool, procedure, workimethod br opetating Technique tnaCis hot Specifically Tecommended by Perkins Is used, you must satlsty yoursolf that It Is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. ‘The information, specifications, and illustrations in this publication are on the basis of information that ‘was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other temss can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job: Perkins'dealersihave'the mosticurrentinformation available. When replacement paris are required for this product Perkins recommends ising Perkins replacement parts -or-parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure (o heed this warming cant lead ty prea ture failures, product damage, personal injury or death.SENR9777-03 Table of Contents Systems Operation Section Engine Design General Information Fuel System Air Inlet and Exhaust System 11 Lubrication System Cooling System Basic Engine .... Electrical System Testing and Adjusting Section Fuel System Fuel System - Inspect, a Airin Fuel - Test Finding Top Center Position for No. 1 Piston Fuel Injection Pump Timing - Cheek... Fuel Injection Pump Timing - Adjust ..... Fuel Quality - Test Fuel System - Prime nn Fuel System Pressure - Test... Air Inlet and Exhaust System Air Inlet and Exhaust System - Inspect... 34 Wastegate - Test .. ‘Compression - Test... 7 22 Engine Valve Lash - InspectiAdjust ... 32 Valve Depth - Inspect .. Valve Guide - Inspect . Lubrication System Engine Oil Pressure - Test «cn Engine Oil Pump - Inspect n- Excessive Bearing Wear - Inspect... Excessive Engine Oil Consumption - inspect Increased Engine Oil Temperature - Inspect .... 38 Soolng System - Check (Overheating)... Cooling System = INSPEC ven on 40. Cooling System - Test Engine Oil Cooler - Inspect i. Water Temperature Regulator - Test a3 Basic Engine Piston Ring Groove - Inspect... ‘Connecting Rod - Inspect... Connecting Rod Bearings - Inspect Main Bearings - Inspect... Cylinder Block - Inspect Cylinder Head - Inspect Piston Height - Inspect Fiywheel - Inspect... Gear Group - Inspect... Electrical System Altemator - Test Battery - Test 3 Table of Contents Electric Starting System - Test 50 Glow Plugs - Tes... ae V-Belt - Test Ss 53 Index Section Index 544 Systems Operation Section Systems Operation Section Engine Design istration 4 oveezes 1104 example of the layout of the valves (Aint valve (8) Exhaust vale 1104 Engine Specification Industrial Type Four cylinder and four stroke ‘Type of combustion. _ Direct injection Bore 105 mm (4.134 inch) StOKE vv- 127 mm (5.00 inch) Displacement. seen 44 L (268 in?) Compression ratio Naturally aspirated Turbocharged Number of cylinders 4 Cylinder arrangement. In-line Firing order sneer 4, 3,4, 2 1104 Engine Specification Genset Type Four cylinder and four stroke ‘Type of combustion .. . Direct injection SENR9777-03 Bore 4105 mm (4.134 inch) Stroke 127 mm (6.00 inch) Displacement .. 4.4L (268 in’) ‘Compression ratio Naturally aspirated ‘Turbocharged 11044 engines ‘Turbocharged 1104C engines. Number of cylinders. Cylinder arrangement ...cccrccrecenee INE Firing order... 13,42 When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction. . Clockwise The front of the engine is opposite the flywheel end ofthe engine. The left side of the engine and the right side of the engine are determined from the flywheel end. Number 1 cylinder is the front cylinder of the engine. ° A 8 ‘stration 2 erineies 1102 oxamplo of to layout ofthe valvos (A) Inlet volvo (8) exnaust vive 1103 Engine Specification Industrial Type ‘Three cylinder and four stroke Type of combUStION nen Ditect injection BORE cennnnnnneeee 105 mam (4.133 inch) Stroke 4127 mm (5.00 inch)SENR9777-03 Displacement 3.3L 201 in’) Compression ratio Naturally aspirated .....ucnninnineninesene 19.26:1 Turbocharged 18.231 Number of cylinders ... Cylinder arrangement In-tine Firing order 1.2.3 1103 Engine Specification Genset TYPE snsnnsneane Three oylinder and four stroke Type of combustion... oe: Direct injection Bore . 105 mm (4.133 inch) StOKE nn veeee 127 mm (5.00 inch) Displacement . 3.3L (201 in’) ‘Compression ratio Naturally aspirated ..... Turbocharged 1103A engines......... ‘Turbocharged 1103C engines Number of cylinders ccc 8 Cylinder arrangement Firing order “12,3 When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following direction. Clockwise The front of the engine is opposite the flywheel end of the engine. The left side of the engine and the right side of the engine are determined from the flywheel end. Number 1 cylinder is the front cylinder of the engine. 5 Systems Operation Section General Information Engine Description Note: When you are ordering new parts, refer to the engine identification number in order to receive the correct parts. Refer to the Operation and Maintenance Manual, “Product Identification Information” for the correct numbers for your engine. ‘The engine cylinders are arranged in-line. The engines are controlled by a mechanically governed fuel injection pump. The cylinder head assembly has one inlet valve and fone exhaust valve for each cylinder. Each valve has ‘one valve spring. The pistons have two compression rings and an oil control ring. Itis important to ensure the correct piston height so that the piston does not contact the cylinder head. ‘The correct piston height also ensures the efficient combustion of fuel. ‘The 1104 engine crankshaft has five main journals. End play is controlled by thrust washers that are located on both sides of the center main bearing. ‘The 1103 engine crankshaft has four main journals. End play is controlled by thrust washers that are located on both sides of the number three main bearing. The timing case has a hole that corresponds with a hole in the crankshaft. Use an alignment pin to find TC. The camshaft gear has a timing hole that corresponds with a timing hole in the timing case. ‘The timing holes ensure that the camshaft and the crankshaft are in time with each other. ‘The crankshaft gear rotates the idler gear. The idler gear rotates the camshaft gear and the fuel injection ump gear. The idler gear for the engine oil pump is rotated by the crankshaft gear. This idler rotates the engine oll pump. ‘The fuel injection pump is a gear-driven pump that is mounted to the back of the front housing. The fuel transfer pump is electrically operated. The fuel transfer pump has an integral fuel fier. The fuel transfer pump is usually located on the left hand side of the cylinder block. Some applications may have the fuel transfer pump and the water separator (if equipped) relocated off the engine. The oll pump is driven by an idler gear. The engine oll pump sends lubricating oil to the main oil gallery. The oll relief valve is internal to the oil pump.6 Systems Operation Section Coolant from the bottom of the radiator passes through the water pump. The water pump is driven by the idler gear. ui ig the Engine NOTICE Failure to follow recommended procedures for han- dling or transporting engines can lead to engine dam- age. To avoid possible engine damage, use the following procedure. When you are lifting or moving the engine, use the following procedures in order to prevent engine damage. 1. Do not tit the engine to an extreme angle unless. the lubricating oil is first drained from the oil pan. 2. Do not tum the engine onto a side or an end surface unless the lubricating oil is first drained from the oil pan. 3. Ifthe oil is not drained prior to tilting the engine or ‘tuming the engine onto a side or an end surface, the luhrieating oil frm the oil pan ean finw into the intake manifold and the cylinder bores. This situation could cause a hydraulic lock in the engine, Hydraulic lock can severely damage the engine. 4, The engine oil should be refilled to the correct, level before the engine is started. SENR9777-03SENR9777-03 1104 Engine Model Views Imastration 3 ‘com (1) Water temperature regulator housing (4) Engine olf cooler (7) Crankshatt pulley {2} Valve mechanism cover (6) Fan awa {€) Ol'pan (G) Fuel transfer pump and fuel er (0) Water pump (6) Engine oi fier8 SENR9777-03 ‘Systems Operation Section iustration 4 | (10) Engine of mor cap (13) atomator (18) Stator motor (11) Exhaust manifold (14) Fhwwhee! housing (12) Turbocharger (18) Fiythost‘SENR9777-03 9 Systems Operation Section 1103 Engine Model Views stration 5 cod (1) Atternator {) Turbocharger oil supety (6) Tuoenargor (2) Fan putoy (4) Turbocharger ait rain (6) Exhaust manifold10 ‘Systems Operation Section SENR9777-03 tmstraton 6 (1) Fuel wanstr pump (9) on mr {2) ot ter cap oi pan {@) Ful ter {@) Crankshat pulley {@) Stator moto {Oh Wator pump (©) Dpstex Fuel System ‘The Delphi DP210 or the Delphi DPG fuel injection pump is installed on the 1104 engine and the 1103 engine. The Delphi STP fuel injection pump is installed on the 1103 engine only. The Delphi DPA or the Bosch EPVE fuel injection pump is installed on the 1104 engine only. rors (10) Water temperature reguator housing The fuel transfer pump draws fuel from the fuel tank and through the water separator. When the fuel goes. through the water separator, any water in the fuel will go to the bottom of the bowl. The fuel transfer pump ‘sends the fuel at a low pressure to the fuel fer. From the fuel fier, the fuel goes through the supply line to the fuel injection pump. ‘The fuel injection pump sends fuel through the high pressure fuel line to each of the fuel injectors. The fuel injector sprays the fuel into the cylinder. Fuel that is not injected flows through the fuel retum line to the top of the fuel filter, back to the fuel tank.SENR9777-03 ‘The engine must not be started until the fuel injection ‘pump is full of fuel that is free of air. The fuel injection ump requires fuel for lubrication. The precision parts of the pump are easily damaged without lubrication. ‘The fuel system must be primed when any of the following conditions ocour: + The fuel filter is changed. + The fuel line is removed. + The fuel injection pump is removed. Fuel System Components Fuel Injection Pump General Operation ‘The fuel injection pump is a pressurized system that is totally enclosed. The pump sends the correct ‘amount of fuel under high pressure atthe correct time through the fuel injectors tothe individual cylinders. The fuel injection pump regulates the amount of fuel that is delivered to the fuel injectors. This action controls the engine rpm by the governor setting or the position of the throttle contra ‘The fuel lines to the fuel injectors are equal lengths. This ensures even pressure and correct injection timing at each fuel injector. During operation, extra fuel is used as coolant and lubricant for moving parts of the pump. The extra fuel is circulated through the pump housing. The extra fuel is then returned to the fuel tank. ‘The Delphi DP210, OPA, DPG and STP fuel injection pumps must be serviced by an authorized Delphi technician. For repair information, contact your Perkins dealer or contact your Perkins distributor. High idle and low idle of the fuel injection pump are factory set. Idle adjustments can not be made to the fuel pump. The Delphi DP210 fuel injection pump hhas a boost control. The Delphi DP210, DPA, DPG ‘and STP fuel injection pumps have an engine stop solenoid and a feature that vents air from the pump. ‘The Delphi DP210 and STP fuel injection pumps have a cold starting aid. The cold starting aid advances the timing of the pump when the engine is cold. The cold starting aid Is electrically operated, Cold Start Advance Unit The cold start advance unit holds the timing of the fuel injection pump in an advance position when the engine is cold. 1" Systems Operation Section The coolant switch for the cold start advance unit is, on the water temperature regulator housing on the left side of the engine. When the engine is cold, the sender unit is energized in order to advance the fuel injection pump timing for the cold start operation. When the correct temperature is achieved the sender unit is, de-energized and the fuel injection pump timing is returned to the normal operating position. If the switch falls in the closed position, the engine will run with advanced fuel injection timing. The engine will have higher cylinder pressure and engine damage may result. IF the switch fails in the open position the engine will run with the fuel injection timing in the normal operating position. The engine will be more difficult to start. When the engine is cold the engine might ‘emit white smoke. woxer2802 Air Inlet and Exhaust System 2 7 ‘stration 7 cme Air inlet and exhaust system (typical example) (1) Exhaust manifold (2) Intake manifola {G) Engine cyinders (3) Aine (G) Turbocharger compressor wheel (6) Turbocharger tune wheel (7) Exhaust outlet Engines which are naturally aspirated pull outside air through an air cleaner directly into the inlet manifold (2). The air flows from the intake manifold to the engine cylinders (3). The fuel is mixed vith the air in the engine cylinders. After the fuel combustion occurs in the engine cylinder, the exhaust gases flow directly to the outside air through the exhaust manifold (1)2 Systems Operation Section ‘Turbocharged engines pull outside air through an air cleaner into the air intake (4) ofthe turbocharger. The suction is caused by the turbocharger compressor wheel (5). Then, the turbocharger compressor wheel ‘compresses the ai. The alr flows through the intake ‘manifold (2) which directs an even distribution of the air to each engine cylinder (3). Airis pulled into the ‘engine cylinder (3) during the intake stroke of the piston. Then, the air is mixed with fuel from the fuel injectors. ach piston makes four strokes: 4. Intake 2. Compression 3. Power 4, Exhaust ‘The sequence of the strokes by all of the pistons in all of the engine cylinders provide constant air flow through the inlet system during the engine operation. ‘The exhaust stroke and the timing of the valve mechanism pushes combustion gases through the ‘open exhaust valve into the exhaust manifold (1). ‘The exhaust gases flow through the blades of the turbocharger turbine wheel (6) which causes the turbine wheel and the compressor wheel to tum, ‘Then, the exhaust gases flow through the exhaust outlet (7) of the turbocharger to the outside. ‘The air inlet system is also equipped with a crankcase ventilation system. The intake strokes of the pistons. pull in atmospheric air to the crankcase. Turbocharger Note: The turbocharger is not serviceable. A turbocharger increases the temperature and the density of the air that is sent to the engine cylinder. This condition causes a lower temperature of ignition to develop earlier in the compression stroke. The ‘compression stroke is also timed in a more accurate way with the fuel injection. Surplus air lowers the temperature of combustion. This surplus air also provides internal cooling, A turbocharger improves the following aspects of engine performance: + Power output is increased. + Fuel efficiency is improved. + Engine torque is increased. SENR9777-03 + Durability of the engine is improved. ‘+ Emissions from the engine are reduced. 123 45 6 7 8 9 f 0 Gy 1 Iustraton 8 ene ‘Components ofa turbocharger typical example} (1) Atenas (2) Compressor housing () Compressor whoo! (@) Boanng (5) Oi inlet port (6) Beanng (@) Turbine housing (@) Turbine whoo! (9) Exhaust outlet (10) Ot outet port (14) Exhaust init ‘A turbocharger is installed between the exhaust and intake manifolds. The turbocharger is driven by ‘exhaust gases which flow through the exhaust inlet (11), The energy of the exhaust gas turns the turbine wheel (8). Then, the exhaust gas flows out of the turbine housing (7) through the exhaust outlet (2). ‘The turbine wheel and the compressor wheel (3) are installed on the same shaft. Therefore, the turbine wheel and the compressor wheel rotate at the same rpm. The compressor wheel is enclosed by the compressor housing (2). The compressor wheel compresses the intake air (1). The intake air flows into the engine cylinders through the inlet valves of the cylinders. The oll from the main gallery of the cylinder block flows through the oil inlet port (6) in order to lubricate the turbocharger bearings (4) and (6). The pressurized oil passes through the bearing housing of the turbocharger. The cil is returned through the oil outlet port (10) to the oil pan.SENR9777-03 ‘The turbocharger has a wastegate. The wastegate is controlled by the boost pressure. This allows some of the exhaust to bypass the turbocharger at higher engine speeds. The wastegate is a type of valve that automatically opens at a preset level of boost pressure in order to allow exhaust gas to flow around the turbine. The wastegate allows the design of the turbocharger to be more effective at lower engine speeds. ‘The wastegate is controlled by a diaphragm. One ‘side of this diaphragm is open to the atmosphere, ‘The other side of this diaphragm is open to the manifold pressure. Cylinder Head And Valves The valves and the valve mechanism control the flow of the air and the exhaust gases in the cylinder during engine operation. The cylinder head assembly hhas two valves for each cylinder. Each valve has one valve spring, The ports for the inlet valves are on the left side of the cylinder head. The ports for the exhaust valves are on the right side of the cylinder head. Steel valve seat inserts are installed in the cylinder head for both the inlet and the exhaust valves. The valve seat inserts can be replaced. ‘The valves are installed in valve quides. The valve guides can be replaced. The exhaust valve guide has ‘a counterbore in order to prevent the seizure of the valve stem. The seizure of the valve stem is caused bby a buildup of carbon under the head of the valve. ‘The inlet and the exhaust valves are opened and closed by the rotation and movement of the following ‘components: + Crankshaft + Camshaft © Valve lifters + Pushrods + Rocker arms * Valve springs ‘The camshaft gear is driven by the crankshaft gear. ‘The camshaft and the crankshaft are timed together. When the camshaft tums, the valve lifters and the pushrods are moved up and down. The pushrods move the rocker arms. The movernent of the rocker ‘arms open the valves. The opening and closing of the valves is timed with the fing sequence of the engine. The valve springs push the valves back to the closed position. 13 Systems Operation Section14 SENR9777-03 Systems Operation Section Lubrication System tastration 9 soronssea Flow diagram ofthe lubrication system for the 1104 engine‘SENR9777-03 15 ‘Systems Operation Section Mustration 10 Flow diagram of tho lubneation system forthe 1103 engine Lubricating oil from the oil pan flows through a strainer and a pipe (8) to the suction side of the engine oil pump (10). Pressure for the lubrication ‘system Is Supplied by the oll pump . The crankshaft gear (13) drives a lower idler gear (12). The lower idler gear drives the oil pump gear (11). The pump fhas an inner rotor and an outer rotor. The axis of rotation of the rotors are off-center relative to each other. There is an interference fit between the inner rotor and the drive shaft. ‘The inner rotor has five lobes which mesh with the six lobes of the outer rotor. When the pump rotates, the distance increases between the lobes of the outer rotor and the lobes of the inner rotor in order to create suction. When the distance decreases between the lobes, pressure is created. ‘oovorears ‘The lubricating oll flows from the outlet side of the oll pump (10) through a passage to the oil filter head (7). The oll then flows from the oll fiter head through a passage 0 a plale lype oil evoler for the 1104 engine, (or a modine oil cooler (3) for the 1103 engine. The oil cooler is located on the left side of the cylinder block. From the oil cooler, the oll returns through a passage to the oil filter head. The oil then flows through a bypass valve that permits the lubrication system to function if the oil iter becomes blocked. Under normal conditions, the oil then flows to the oil fiter (8).16 Systems Operation Section The cil fows from the oil fter through a passage that is drilled across the cylinder biock to the oil gallery ). The oil gallery is drilled through the total length ofthe left side of the cylinder block. Ifthe oll iter is ‘on the right side of the engine, the oll flows through ‘a passage that is driled across the cylinder block to the pressure gallery Lubricating oil from the oil gallery flows through high pressure passages to the main bearings of the crankshaft (5). Then, the oil flows through the passages in the crankshaft to the connecting rod bearing journals (6). The pistons and the cylinder bores are lubricated by the splash of oll and the cil mist Lubricating oil from the main bearings flows through passages in the cylinder block to the journals of the ‘camshaft. Then, the oil flows from the second journal of the camshaft (2) at a reduced pressure to the cylinder head. The oil then flows through the center of the rocker shaff (1) to the rocker arm levers. The valve stems, the valve springs and the valve lifters are lubricated by the splash and the oll mist. ‘The hub of the idler gear is lubricated by oil from the oll gallery. The timing gears are lubricated by the splash from the oil ‘An extemal ine from the cylinder block supplies oll 10 the turbocharger. The oil then flows through a return line to the oll pan. Engines have piston cooling jets that are supplied with oil from the oil gallery. The piston cooling jets ‘spray lubricating oil on the underside of the pistons in order to cool the pistons. SENR9777-03SENR9777-03 7 Systems Operation Section Cooling System Mustraton 14 sn0ses4er Flow diagram of te cooling system forthe 1104 engine18 ‘Systems Operation Section SENR9777-03 Iustration 12 Flow diagram of te cooling system forthe 1103 engine ‘The coolant flows from the bottom of the radiator to the centrifugal water pump. The water pump assists in the flow of the coolant through the system. The ‘water pump is installed on the front of the timing case. The water pump is gear-driven by the fuel injection pump gear. ‘The water pump forces the coolant through a passage in the front of the timing case to the water Jacket in the top left side of the cylinder block. The ‘coolant continues to the rear of the cylinder block. ‘The main flow of the coolant passes from the rear of, the cylinder block into the rear of the cylinder head. ‘The coolant flows forward through the cylinder head and into the water temperature regulator housing. if the water temperature regulator is closed, the coolant goes directly through a bypass to the inlet side of the water pump. If the water temperature regulator is open, the bypass is closed and the coolant flows to the top of the radiator. 1103 engines From the rear of the cylinder block, some of the coolant passes into the modine oil cooler (if equipped). The modine oil cooler is located on the [eft side of the cylinder block. The coolant passes through the oll cooler before being retumed through an external line to the inlet side of the water pump. 1104 engines From the rear of the evlinder block. some of the coolant passes into the oil cooler. The oil cooler is located on the left side of the cylinder block with no external lines. The coolant flows around the element of the oil cooler before being returned to the rear of the cylinder block.SENR9777-03 Basic Engine Cylinder Block and Cylinder Head ‘The cylinder block for the 1104 engine has four cylinders which are arranged in-line. ‘The cylinder block for te 1103 engine has three cylinders which are arranged in-line. The cylinder block for the 1104 engine has five ‘main bearings which support the crankshaft. Thrust washers on both sides of the center main bearing control the end play of the crankshaft. The cylinder block for the 1103 engine has four ‘main bearings which support the crankshaft. Thrust ‘washers on both sides of the number three main bearing control the end play of the crankshaft. A cylinder head gasket is used between the ‘engine block and the cylinder head in order to seal ‘combustion gases, water, and cll ‘The engine has a cast iron cylinder head. The inlet ‘manifold is integral within the cylinder head. An inlet valve and an exhaust valve for each cylinder are controlled by a pushrod valve system. The ports for the inlet valves are on the left side of the cylinder head. The ports for the exhaust valves are on the right side of the cylinder head. Pistons, Rods The pistons have a combustion chamber in the top of the piston in order to provide an efficient mix of fuel and air. The piston pin is off-center in order to reduce the noise level. igs, and Connecting ‘The pistons have two compression rings and an oil ccontrol ring. The groove for the top ring has a hard metal inset in order (o reduce wear of the groove. ‘The skirt has a layer of graphite in order to reduce wear. ‘The correct piston height is important in order to ‘ensure that the piston does not contact the cylinder head. The correct piston height also ensures the efficient combustion of fuel which is necessary in ‘order to conform to requirements for emissions. Engines are equipped with connecting rods that have bearing caps that are fracture split. The bearing caps ‘on fracture split connecting rods are retained with torx serews. Connecting rads with bearing caps that are fracture split have the following characteristics: 19 ‘Systems Operation Section ‘+ Higher integrity for the rod + The splitting produces an accurately matched surface on each side for improved strength. + Modem design ‘The connecting rod is matched to each cylinder. ‘The piston height is controlled by the length of the connecting rod. Six different lengths of connecting rods are available in order to attain the correct piston height. The different lengths of connecting rods are ‘made by machining the small end bearing off-center in order to form an eccentric bearing. The amount of the eccentricity of the bearing creates the different lengths of the connecting rods. Crankshaft ‘The crankshaft changes the linear energy of the pistons and connecting rods into rotary torque in order to power external equipment. A gear at the front of the crankshaft drives the timing gears. The crankshaft gear tums the idler gear which then turns the following gears: + Camshaft gear ‘+ Fuel injection pump + Lower idler gear which turns the gear of the lubricating oll pump Lip type seals are used on both the front of the crankshaft and the rear of the crankshaft. Camshaft ‘The engine has a single camshaft. The camshaft is driven by an idler gear in the front housing, The camshaft uses only one bearing on the front journal ‘The other journals rotate in the bore of the cylinder block. The front bearing and the camshaft bores in the cylinder block support the camshaft. As the camshaft turns, the camshaft lobes move the valve Syctem components. The valve system componente move the inlet and exhaust valves in each cylinder. ‘The camshaft gear must be timed to the crankshaft gear. The relationship between the lobes and the cams gear causes the valves in each cylinder to be opened and closed at the correct time. The relationship between the lobes and the camshaft gear also causes the valves in each cylinder to close at the correct time.20 Systems Operation Section Electrical System The electrical system is a negative ground system, ‘The charging circuit operates when the engine is running. The altemator in the charging circuit produces direct current for the electrical system. Starting Motor ustretion 13, ‘gooeeee20 1277 Stain Motor (1) Termial far cannecton of the battory cable (2) Terminst tar connection of the igniton swith SENR9777-03‘SENR9777-03 241 Systems Operation Section X > 2 | / = ¢ ] +) o = Mustration 14 eee: 2 Sena Mor Cr embeloremecinn fe pon 2 Tel coma ati Sere He The starting motor turns the engine flywheel. The Alternator pm is high enough in order to initiate a sustained operation of the fuel ignition in the cylinders. The starting motor has a solenoid. When the ignition switch is activated, voltage from the electrical system will cause the solenoid to engage the pinion in the = flywheel ring gear of the engine. When the pinion {gear is engaged in the flywheel ring gear, the electrical contacts in the solenoid close the circuit between the battery and the starting motor. This. ‘causes the starting motor to rotate. This type of activation is called a positive shift. When the engine begins to run, the overrunning fe clutch of the pinion drive prevents damage to the -— armature, Damage to the armature is caused by excessive speeds. The clutch prevents damage by stopping the mechanical connection. However, the pinion will stay meshed with the ring gear until the ignition switch is released. A spring in the overrunning clutch returns the clutch to the rest position. ‘mustravon 15, spnsona4 (1) Shalt for mounting the pulley The alternator produces the following electrical output: + Three-phase + Fulkwave + Rectified22 Systems Operation Section The alternator is an electro-mechanical component. The alternator is driven by a drive belt from the crankshaft pulley. The alternator charges the storage battery during the engine operation. ‘The alternator converts the mechanical energy and the magnetic energy into electrical energy. This conversion is done by rotating a direct current electromagnetic field on the inside of a three-phase stator. The electromagnetic field is generated by electrical current flowing through a rotor. The stator generates AC electrical power. ‘The alternating current is changed to direct current by a three-phase, full-wave reciifer. Direct current flows to the output terminal of the alternator. The rectifier has three exciter diodes. The direct current is used for the charging process. A regulator is installed on the rear end of the alternator. Two brushes conduct current through two slip rings. The current then flows to the rotor field. A ‘capacitor protects the rectifier from high voltages. The alternator is connected to the battery through the ignition switch. Therefore, altemator excitation ‘occurs when the switch is in the ON position. SENR9777-03SENR9777-03 Testing and Adjusting Section Fuel System Fuel System - Inspect ‘A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance. 4. Check the fuel level in the fuel tank. Ensure that the vent in the fuel cap is not filled with dirt 2. Check all fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty bends. ‘Verify that the fuel return line is not collapsed 3. Inspect the fuel fter for excess contamination. If necessary, install a new fuel filter. Determine the source of the contamination, Make the necessary repairs. 4, Service the primary fuel fiter (if equipped). 5. Remove any air that may be in the fuel system. Refer to Testing and Adjusting, “Fuel System - ‘orese200 Air in Fuel - Test This procedure checks for ar in the fuel system. This procedure also assists in finding the source of the air. 1. Examine the fuel system for leaks. Ensure that the fuel line fitings are properly tightened. Check the fuel level in the fuel tank, Air can enter the fuel system on the suction side between the fuel transfer pump and the fuel tank. Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. 23 Testing and Adjusting Section 2. Install a suitable fuel flow tube with a visual sight ‘gauge in the fuel return line. When possible, install the sight gauge in a straight section of the fuel line that is at least 304.8 mm (12 inches) long. Do not install the sight gauge near the following devices, that create turbulence: + Elbows + Relief valves + Check valves Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel that is present in the sight gauge, prime the fuel ‘system. Refer to Testing and Adjusting, “Fuel System - Prime" for more information. if the engine starts, check for air in the fuel at varying engine speeds. When possible, operate the engine under the conditions which have been suspect. NX Acceptable Hill mn ~ Acetate ‘ustraton 16 gonsrasst (1) A steady stroam of smal bubbles with a diamotor of approximately 1.60 mm (0.003 inch isan acceptable amount of air inthe fuel (2) Bubbles witha diameter of approximately 6.95 mm (0.250 inch) tare also acceptable i tere Is two seconds to three seconds intervals between bubbies (3) Excessive air bubbles inthe fuel are not acceptable 3. If excessive air is seen in the sight gauge in the fuel return line, install a second sight gauge at the inlet to the fuei transfer pump. Ifa second sight ‘gauge is not available, move the sight gauge from the fuel return line and install the sight gauge at the inlet to the fuel transfer pump. Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If the engine starts, check for air in the fuel at varying engine speeds.24 Testing and Adjusting Section ‘SENR9777-03 If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after the fuel transfer pump. Refer to the Testing and Adjusting, "Fuel System - Prime”. If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction side of the fuel system. To avoid personal injury, always wear eye and face protection when using pressurized ait NOTICE ‘To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the fuel tank. 4, Pressurize the fuel tank to 36 kPa (5 psi). Do ot use more than 55 kPa (8 psi) in order to avoid damage to the fuel tank. Check for leaks the fuel ines between the fuel tank and the fuel ‘transfer pump. Repair any leaks that are found. Check the fuei pressure in order to ensure that the fuel transfer pump is operating properly. For information about checking the fuel pressure, see Testing and Adjusting, “Fuel System Pressure - Test’ 5. If the source of the air is not found, disconnect the supply line from the fuel tank and connect an external fuel supply to the inlet of the fuel transfer ump. If this corrects the problem, repair the fuel ‘tank or the stand pipe in the fuel tank, vowssat4 Finding Top Center Position for No. 1 Piston abet Required Tools: Part Naotor Part Description ty 27610211 | Crankshaft timing pin 1 (27810242 | Camshaft timing pin 7 ‘mustraton 17 sp092a080 (1) Hole for crankshaft pin (2) Hole fr camshat pi 1. Remove the valve mechanism cover, the glow plugs, and the cover for the front housing, Note: The crankshaft timing pin can be inserted with he crankshall pulley sill on the engine. 2. Rotate the crankshaft in the normal direction of the engine until the inlet valve of the No. 4 cylinder has just opened and the exhaust valve of the No. 4-cylinder has not completely closed. 3. Carefully rotate the crankshaft in the normal direction of the engine in order to align the hole in the crankshaft with the hole in the cylinder block and the timing case. Insert the 27610211 Crankshaft Timing Pin fully into the hole in the ‘crankshaft web, 4, Insert the 27610212 Camshaft Timing Pin through the hole in the camshaft gear and into the body of the timing case. The engine is set at the top center position for No. 1 piston. Note: The camshaft gear can rotate a small amount when the pin is installed, ‘5. Remove the timing pins from the camshaft gear land the crankshaft web.SENR9777-03 Fuel Injection Pump Timing - Check Delphi DP210, Delphi DPA, Delphi DPG and Delphi STP Fuel Injection Pumps Note: The Delphi DP210, Delphi DPA, Delphi DPS and Delphi STP fuel injection pump timing cannot be checked. If you suspect that the fuel injection pump timing is incorrect, contact your Perkins dealer or your Perkins distributor for further information. Note: The Delphi DPA fuel injection pump is only installed on the 1104 engine. Delphi 0P210, Delphi DPA, Delphi DPG and Delphi STP fuel injection pumps must be serviced by an authorized Delphi technician. For repair information, contact your Perkins dealer or your Perkins distributor. The intemal adjustment for the [pump timing is tamper proof. High idle and low idle are factory set. Idle adjustments cannot be made to the fuel pump. Bosch EPVE Fuel Injection Pump Note: The Bosch EPVE fuel injection pump is only instalied on the 1104 engine. “ablo2 Required Tools: Neer Part Description ay Bosch EPVE fuel injection pump 27610248 | Bs 1 1. Set the number one piston at the top center piston on the compression stroke. Refer to Testing and Adjusting. "Finding Top Center Position for the No. 1 Pistion” for the procedure. 2. Remove the high pressure fuel lines from the fuel injection pump. 25 Testing and Adjusting Section Iustration 18, snosee405 (1) Plog stration 19| oe (2) Bosch EPVE tue injection pump timing sdaper (8) Diet naictor 3, Remove the plug (1) and the washer from the rear of the fuel injection pump and install 27610248 fuel injection pump timing adapter (2). Install a suitable dial indicator (3) into 27610248 fuel injection pump timing adapter. Set the dial Indicator to approximately 3 mm (0.1181 inch). 4, Rotate the crankshaft counterclockwise until the dial indicator (3) indicates that the plunger of the fuel injection pump is at the bottom of the stroke. Set the dial indicator (3) to zero.26 Testing and Adjusting Section 5. Rotate the crankshaft clockwise, until the crankshaft timing pin can be pushed into the hole in the crankshaft web. 6. With the engine set at the Top Center Position for the No. 1 piston, check the reading on the dial indicator (3). Refer to Specifications, "Fuel Injection Pump" for the correct reading for the plunger. 7. If the fuel injection pump timing is correct remove the dial indicator (9). Remove 27610248 fuel injection pump timing adapter from the fuel injection pump. Install a new washer to the plug and install the plug in the back of the fuel injection pump. Refer to Specifications, “Fuel Injection Pump” for the correct torque. 8. Install the high pressure fuel lines on the fuel injection pump. Eliminate all air from the fuel system. Refer to Testing and Adjusting, “Fuel ‘System - Prime". 9. Ifthe fuel injection pump timing is incorrect, refer to Testing and Adjusting, “Fue! Injection Pump Timing - Adjust”. Fuel Injection Pump Timing - Adjust Delphi DP210, Delphi DPA, Delphi DPG and Delphi STP Fuel Injection Pumps ‘The Delphi DP210, Delphi DPA, Delphi DPG and. Delphi STP fuel injection pumps must be serviced by an authorized Delphi technician. For repair information, contact your Perkins dealer or your Perkins distributor. The intemal adjustment for the pump timing is tamper proof. High idle and low idle are factory set. Idle adjustments can not be made to the tuel pump. Bosch EPVE Fuel Injection Pump Note: The Bosch EPVE fuel injection pump is only installed on the 1104 engine. ‘SENR9777-03 Tobie 3 Required Tools Part a Part Description ay Bosch EPVE fuel injection pump 27610248 | ming adapter 3 Note: This procedure must only be carried out by a person with the correct training, Note: Do net rotate the fuel injection pump if the fuel injection pump shaft is locked. 1. Set the number one piston at the top center on the compression stroke. Refer to Testing and ‘Adjusting, “Finding Top Center Position for the No. 1 Pistion” for the procedure. 2. Remove the rocker shaft. Refer to Disassembly and Assembly, “Rocker Shaft and Pushrods". 3. Remove the high pressure fuel lines from the fuel injection pump. ‘mustravon 20 spnsseaae (1) Plug‘SENR9777-03 a Testing and Adjusting Section Imustration 24 ‘possezz7 (2) Bosch EPVE fue injection timing adapter (@) Dial indicator 4, Remove the plug (1) and the washer from the rear of the fuel injection pump and install the 27610248 fuel injection pump timing adapter (2). Install a suitable dial indicator (3) into the 27610248 fuel injection pump timing adapter. Set the dial indicator to approximately 3 mm (0.1181 inch). 5. Ensure that the timing pins have been removed from the engine. 6. Rotate the crankshaft counterclockwise when the crankshaft is viewed from the front of the engine. Carefully rotate the crankshaft until the dial indicator (3) indicates that the plunger of the {uel injection pump is at the bottom. Set the dial indicator (3) to zero. 7. Rotate the crankshaft clockwise, until the required lift on the plunger is achieved. Refer to Specifications, “Fuel Injection Pump" for the correct reading, ‘ustraon 22 ‘so085240 (4) Washer (6) Locking serow 8. Lock the fuel injection pump shaft. In order to lock the shaft of the Bosch EPVE fuel injection pump, loosen the locking screw (5) and remove the washer (4). Tighten the locking screw lo 31 Nem (23 Ib 1). Ensure Ural ne needle of the dial indicator has not moved. 9. Remove the water pump. Refer to Disassembly ‘and Assembly, “Water Pump - Remove and Install”. 10, Remove the front cover. Refer to Disassembly ‘and Assembly, “Front Cover - Remove and Install’. 11. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, “Fuel Injection pump. ~ Remove". ‘stration 23 fama (O) Keyway28 Testing and Adjusting Section Inustraton 24 pose2es 7) Outlet Note: A key should not be installed in the keyway (6). Note: If the fuel injection pump is on the correct stroke, the keyway (6) is toward the outlet (7). 12, Set the number one piston at the top center piston on the compression stroke. Refer to Testing and Adjusting, “Finding Top Center Position for the No. 1 Pistion’” for the procedure. 13, Install the fuel injection pump gear. Refer to Disassembly and Assembly, “Fuel Injection pump = Install” 14. Install the front cover. Refer to Disassembly and ‘Assembly, “Front Cover - Remove and Install”. 15. Install the water pump. Refer to Disassembly and ‘Assembly, “Water Pump - Remove and Install. 16, Install a new washer to the plug and install the plug in the back of the fuel injection pump. Refer to Specifications, “Fuel Injection Pump" for the correct torque. 17. Install the rocker shaft. Refer to Disassembly and ‘Assembly, “Rocker Shaft and Pushrods” Install the high pressure fuel lines on the fuel jjection pump. Eliminate all air from the fuel system. Refer to Testing and Adjusting, “Fuel ‘System - Prime”. ‘SENR9777-03 Fuel Quality - Test Use the following procedure to test for problems regarding fuel quality: 41. Determine if water and/or contaminants are present in the fuel. Check the water separator (if ‘equipped). Ifa waier separator is not present, proceed to Step 2. Drain the water separator, if necessary. A full fuel tank minimizes the potential for overnight condensation, Note: A water separator can appear to be full of fuel when the water separator is actually full of water. 2. Determine if contaminants are present in the fuel. Remove a sample of fuel from the bottom of the fuel tank. Visually inspect the fuel sample for contaminants. The color of the fuel is not necessarily an indication of fuel quality. However, fuel that is black, brown, and/or similar to sludge ‘can be an indication of the growth of bacteria or oil contamination. In cold temperatures, cloudy fuel indicates that the fuel may not be suitable for the operating conditions. Refer to Operation and. Maintenance Manual, “Fuel Recommendations” for more information. 3. If fuel quality is stil suspected as a possible ‘cause of problems regarding engine performance, disconnect the fuel inlet line, and temporarily ‘operate the engine from a separate source of fuel that is known to be good. This will determine if the problem is caused by fuel quality. If fuel ‘quality is determined to be the problem, drain the fuel system and replace the fuel filters. Engine performance can be affected by the following ‘characteristics: + Cetane number of the fuel + Air in the fuel + Other fuel characteristies vor214009 Fuel System - Prime If air enters the fuel system, the air must be purged before the engine can be started. Air can enter the fuel system when the following events occur: + The fuel tank is empty or the tank has been partially drained during normal operation.SENR9777-03 + The low pressure fuel lines are disconnected. + Aleak exists in the low pressure fuel system during engine operation. + The fuel flter or the fuel pump is replaced. + The high pressure fuel lines are disconnected. Delphi DP210, Delphi DPA, Delphi DPG and Delphi STP ‘The Delphi DP210, Delphi DPA, Delphi DPG and Delphi STP fuel injection pumps will eliminate the air from the fuel system automatically. Position the starting switch to the RUN position for three minutes. Air in the fuel and the fuel lines will be purged from the system. Bosch EVPE The Bosch EPVE fuel injection pump will not eliminate air automatically from the fuel system. the following procedure must be used. + Remove the valve mechanism cover. ‘+ Tum the start switch to the RUN position for three minutes. Then return the start switch to the OFF position, + Loosen the high pressure lines at the fue! injectors. + Operate the starting motor until fuel free from air comes from the connections. ‘+ Tighten the connections for the fuel injectors. Refer to Specifications, “Fuel injection Lines”, + Operate the engine and check for leaks. Fit the valve mechanism cover. 29 Testing and Adjusting Section Fuel System Pressure - Test & tustraton 25 sooeaeres (A and 6) Fuel outlet (G1) Fu transfer pump (2) Ful tor ‘The pressure test measures the output pressure of the fuel transfer pump. Low fuel pressure and starting difficulty may be indications of problems with the fuel priming pump. Check the Function of the Fuel Transfer Pump 41. Make a note of the location of the fuel lines from the fuel transfer pump. Remove the to lines from the outlets (A) and (8). 2. Connect two lenaths of 5/16 inch rubber hose to ‘outlets (A) and (B). Place the hoses into a suitable container that is capable of holding 3 L (3.17 qt) of fuel, 3. Energize the fuel transfer pump until a constant flow of fuel is running from the outlet for the supply for the fuel injection pump. Note: The flow from the outlet for the return for the fuel tank wall have a slower tlow rate. 4, Measure the combined flow of both outlets with a stopwatch. Fuel flow should be a minimum of 2 Limin (0.53 US gpm). 5. Ifthe combined flow is less than 2 Umin (0.53 US gpm), repair the pump or replace the pump. 6. Reconnect the outlet lines in the correct positions. 7. Start the engine and check for any leakage of fuel ‘or air from the fuel lines.30 Testing and Adjusting Section Check the Function of the Pressure Regulator 4. Remove the fuel line from the outlet for the supply for the fuel injection pump (B). 2. Install a pipe with a tap for a pressure gauge. Connect a0 to 80 kPa (0 to 12 psi) pressure gauge. 3. Start the engine and run the engine at idle for two minutes in order to remove any trapped air. 4, Record the pressure reading at idle and at rated speed. The minimum pressure reading should be the following values: All Fuel Injection Pumps 25 kPa (3.6 psi) Rated speed nnn 23 KP2 (3.3 psi) Note: The maximum pressure for the fuel injection pump at idle speed or rated speed is 75 kPa (10.9 psi, 5. Reconnect the fuel line. Run the engine at idle for ‘two minutes in order to remove any trapped alr. ‘Check for the following issues if the pressures are outside of the above specifications. * All electrical connections are installed correctly. + There are no leaks in the fuel lines or connections. + The O-ring on the fuel filter housing (2) does not leak. SENR9777-03SENR9777-03 Air Inlet and Exhaust System vorezmns Air Inlet and Exhaust System - Inspect ‘A general visual inspection should be made to the air inlet and exhaust system. Make sure that there are 1 signs of leaks in the system. ‘There will be a reduction in the performance of the ‘engine if there is a restriction in the air inlet system or the exhaust system, PUCCINI Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts. When working on an engine that is running, avoid contact with hot parts and rotating parts. 4. Inspect the engine air cleaner inlet and ducting in order to ensure that the passageway is not blocked or collapsed. 2. Inspect the engine air cleaner element. Replace a dirty element with a clean element. 3. Check for dirt tracks on the clean side of the engine air cleaner element. If dirt tracks are observed, contaminants aré tiowing past the element. 34 Testing and Adjusting Section Wastegate - Test Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. ‘stration 26 Note: The turbocharger is a nonserviceable item. ‘The pressure for the wastegate can be checked, but not adjusted 1. Use a suitable magnetic base dial indicator (1). Align the dial gauge to the actuator rod (2). 2. Remove the air hose to the actuator (3). Install an airline that can be adjusted in order to give the correct pressure, Note: Do not exceed 205 kPa (30 psi) in order to check the actuator. Refer to the Specification, “Turbocharger” topic for information on the correct pressure setting for your actuator. 3. Carefully apply the air pressure until the air pressure has moved the rod 1 mm (0.0394 inch). Check that the air pressure is correct for your ‘turbocharger.32 Testing and Adjusting Section 4, For more information on installing a new turbocharger, contact your Perkins dealer or your Perkins distributor. The cylinder compression test should only be used in ‘to compare the cylinders of an engine. if one or more cylinders vary by more than 350 kPa (51 psi), the cylinder and related components may need to be repaired. ‘A compression test should not be the only method ‘which is used to determine the condition of an engine. Other tests should also be conducted in order to determine if the adjustment or the replacement of ‘components is required. Before the performance of the compression test, make sure that the following conditions exist: + The battery is + The battery is fully charged. ‘good condition. +The starting motor operates correctly. + The valve lash is set corretly + All fuel injectors are removed. +The fuel supply is disconnected 1. Install a gauge for measuring the cylinder ‘compression in the hole for a fuel injector. 2. Operate the starting motor in order to tum the engine. Record the maximum pressure which is. indicated on the compression gauge. 3. Repeat Steps 1 and 2 for all cylinders. SENR9777-03 Engine Valve Lash - Inspect/Adjust POG To prevent possible injury, do not use the starter to turn the flywheel. Hot engine components can cause buns. Allow additional time for the engine to cool before mea- suring valve clearance. Valve Lash Set Valve lash setting Inlet valve ._0.2 mm (0.008 inch) Exhaust valve (0.45 mm (0.018 inch) Refer to Systems Operation, “Engine Design” for the location of the cylinder valves. Valve Lash Adjustment Ifthe valve lash requires adjustment several times in a short period of time, excessive wear exists in ‘a different part of the engine. Find the problem and make necessary repairs in order to prevent more damage to the engine. Not enough valve lash can be the cause of rapid \wear of the camshaft and valve lifters. Not enough valve lash can indicate that the seats for the valves are worn. Valves become worn due to the following causes: ‘+ Fuel injectors that operate incorrectly + Excessive dirt and oil are present on the filters for the inlet air. ‘+ Incorrect fuel settings on the fuel injection pump. + The load capacity of the engine is frequently exceeded ‘Too much valve lash can cause broken vaive stems, springs, and spring retainers. Too much valve lash can be an indication of the following problems: + Worn camshaft and valve lifters + Wom rocker armsSENR9777-03 + Bent pushrods + Broken socket on the upper end of a pushrod. * Loose adjustment screw for the valve lash Ifthe camshaft and the valve lifters show rapid wear, ook for fuel in the lubrication oil or dirty lubrication oil as a possible cause. The valve lash is measured between the top of the valve stem and the rocker arm lever. Note: An adjustment is not necessary if the ‘measurement of the valve lash is in the acceptable range. Inspect the valve lash while the engine is ‘stopped. The temperature of the engine does not change the valve lash setting. Note: When the following procedures are performed, the front housing must be installed. Inustration 27 spraners Sting the valve lash (1) Adjustment screw (2) Footer gauge Valve Lash Adjustment for the 1104 engine 1. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install’. 2. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the No. 4 cylinder has opened and the exhaust valve of the No. 4 cylinder has not completely closed measure the valve lash of the inlet vaive and the exhaust valve of the No. 1 cylinder. if necessary, make adjustment. 33 Testing and Adjusting Section ‘a. Loosen the valve adjustment screw locknut that is on adjustment screw (1). b, Place the appropriate feeler gauge (2) between the rocker arm and the valve. Turn adjustment screw (1) while the valve adjustment screw locknit is being held from turning. Adjust the valve lash unti the correct specification is achieved, . After each adjustment, tighten the valve ‘adjustment screw locknut while adjustment ‘screw (1) is being held from tuming. 3. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the No. 2 eylinder has opened and the exhaust valve of the No. 2 cylinder has not ‘completely closed measure the valve lash of the inlet valve and the exhaust valve of the No. 3 cylinder. If adjustment is necessary, refer to Steps 2.a, 2.b, ‘and 2.¢ above. 4, Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the No. 1 cylinder has opened and the exhaust valve of the No. 1 cylinder has not ‘completely closed measure the valve lash of the inlet valve and the exhaust valve of the No. 4 cylinder. If adjustment is necessary, refer to Steps 2.a, 2.b, ‘and 2.¢ above. 5. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the No. 3 cylinder has opened and the exhaust valve of the No. 3 cylinder has not completely closed measure the vaive lash of the inlet valve and the exhaust vaive of the No. 2 cylinder. If adjustment is necessary, refer to Steps 2.a, 2b, and 2.¢ above. 6. Install the valve mechaniam cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install”. Valve Lash Adjustment for the 1103 engine 41. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover - Remove and Install”.