moves 55, 0:179, 0206, 0.299 11239, 0.240, 0269,0:310, 0.350 (Dr360 ana OT 402, DIESELENGINES FORM CGES3101 PAYLINE, TRUCK, AGRICULTURAL EQUIPMENT AND GEM APPLICATIONS (Superiader Form CGES310} Due to 2 continuous program of research and devilopi ont, some procedures, ‘specifications and parts may be altered in a constant effort to improve machines, erlodic revisions may be made to this publication and mailed automaticaly to istributors. It is recommended that ustomers contact their distributor for Information on the latest revision. fnuereD Wi URUTED STATES OF AMERICA‘CONSTRUCTION EQUIPMENT PUBLICATIONS INFORMATION ‘THE PUBLICATIONS LISTED ON THE 9ACK OF THIS ORDER FORM ARE AVAILABLE FOR THIS PARTICU: LAR MACHINE(S) PLEASE TEAR QUT THIS PAGE AND CHECK THE PUBLICATIONS DESIRED. FICC IN ALL ‘THE INFORMATION REQUESTED ON THIS ORDER FORM! ‘A PRODUCT PUBLICATION INDEX AND PRICE List IS AVAILABLE TO ALL. CONSTRUCTION EU ING OF PRODUCT PUBLICATIONS INCLUDING OP ERATOR'S NANUALS FOR APPROXIMATELY 270 CONSTRUCTION. EQUIPMENT MACHINES AND (OVER 100 ENGINE POWER UNITS, SPECIAL PUBLICATIONS, SUCH AS SERVICE TOOL, ENGINE DIAGNOSTIC, AIR CONDITIONING, FUEL INJECTION “PUMPS “AND. TURBOCHARGER SER VIGE MANUALS ARE ALSO AVAILASLE AS WELL AS SELECTED OPERATORS AND SERVICE MAN GALS IN THE SPANISH AND FRENCH LANGUAGES, ‘THE CATALOG ALSO CONTAINS A SPECIAL LIST: ING ‘OF AVAILABLE ARCHIVE. PUBLICATIONS SOME GF WHICH DATE BACK TO THE 1830. Peas end me (Check item in box) 1 copy of Product Publications Index and Price List 1 019 104 R20 (or later (Price: $2.00) Poss ar all ints to INTERNATIONAL HOUGH DIVISION ‘DRESSER INDUSTRIES EAST SUNNYSIDE AVENUE LIGERTYVILLE, ILLINOIS 60049 ATTENTION: TECHNICAL PUBLICATIONS NOTE: Enclose check or money order payable to International Hough Dvslon. DO NOT SEND CASH, (Plei low upto 30 des Tor delvery) ORDERS ARE NOT SHIPPED COD. “TYPE or PRINT infomation in the spaces blow, Dee. Amount Encore‘TABLE OF CONTENTS. Longituinal and Cros Seton ‘echnical Dats Service Tool Special Nut and Bolt Torque Data Identtction of atferen Bots Valve Laver Aasmbly ‘Cmahat, lair Ges, Teppets and Push Rode Cylinder Head, Valves and Valve Guides Invake Manifold Exot Maifola Crankease Front Cover snd From Plat Crankcase, Ot Pan, Flyhe! Housing Cranksatt, Bot Play aloe Fiywheal with Ring G Piston, Cylinder Steer anc Connecting Rode owpump Water Pump ‘Thermostat snd Coolant Manifolé ual System ual ejection Pump VAY ual njstion Pump (VE) Injection Nozze ana Holder Iniston Pines Venting the Ful Systm Tuning Ue Checks ‘unsin Schedule Handing over the Engine Alteators Generator and Regulators Starting Motor “Turbocharaae Beeeet " “ 2 Ps 8 “ 61 0 at %2 125 v2 70 180 180 180 181 187 100 190 191 209 218 24‘Aerators and Regulators [tsrntore Operating Inatruetons ‘Aterntors Serving "G1" ‘Alternator Sewing "KI" Balancer Euancr Dive Gear Balance Weiges Bearing Ieee Biow by Values Bot and Wat lenin © {Connecting Rods and Pistons ‘Gankcas Front Gover Grankcns ond O1 Pon GrankenveCountebore Resurfacing Grankense Presre Ghar (Grantahatt, RegrnaingInruction (Gartaneft and bat Pulley Grinder Head GrinserSeoves ylinge Sleeve Proton > ate, Engine Date, Sed Nut and Bolt Torque Dalry Valves (VAI Datvry Vats (VE) Electrical Eqloment Engine, checks Engine, Oats, Engine, Lngjitudinal and Cros Section Engine, Hanging oer Fiywheet Housing Foal System 6 canratrs nd Regulators INDEX ret 12) Iason oan 82 Inpoon Pew i is INagcrioN pu vad me ‘Operation Greta Aree Sevcng etn Scocat 8 Disassembly, a Installation SS Eeing “ining wth il nee ‘ ® rnugcrion Powe ve) Span Tengo Aden 4 Senlene mek B Remo 3 Diem yes LSet ek x OM sont Manos, Cotne tn Ec sonra {in ering te entnton tke Bing ea s Sy Hod Hoar go Novae See ie ) "90 Oil Pan Ot Pan Ot Se Fon ee Ota wr % oF 4 7B tore an Comming Rad 8 200 unin Soa ccesai01 m 100 9 108 Ho no 18 188 125 1B 135 8 a 128 12 123 16 0 2 1, 2 190Special Nutand Bote Torgue Dats ‘Sorting Motor UO}. ‘Serting ttotor UP) Starting Motor Trableshooting Sate Ting Chere 1 Tools, Engine Teansieal Oat, Engines Thermos Timing Tuningp Turpocharae “Turbocheret, Troubleshooting Tala INDEX — Continued Pos ov 218 Yah Laver Assembly FS Vatvesang Vave Gules Be Vanetwn SE Paley ‘ening the Ful Systm Sane Coca ede eet i Sekien Hd fe coo m Pave ies i" 18 22 88LONGITUDINAL SECTION OF ENGINE (4-Cylinder Engine) set 42— Manifold exhaust 443 — Thermostat anor coolant manifold) \ 23 Noztle older 30 — Heating pipe ccess101 [PRINTED IN UNITED STATES OF AMERICA,(CROSS SECTION OF ENGINE (4-Cylinder Engine) Ys so 1x |i J rt 4 2 » ‘8 5 s bs ' 9, 36 He, Ty Yy, Wi, 5 4 18 y aA # a8. 07 689 ‘OGESSIO4 ivteD W UNITED STATES.OF AMERICATre Direction of rotation facing yest (competion rato Compression at starting speed, MPa (PS). Firing order 0-155, 0-179, 'D-208, D=258, D246, 0-268, OT-230 9-310, 0-388, DT-368, oT 402 cooune system ‘Most favorable operating tempera AIR SYSTEM a.m etetionbafore serlng the air eaner LueRicaTine svsreM (it prose a ata sped, Pa (1) Oi pressure at ow ie sped and 90° (104) ‘ol tmperature, Pa PSI Lebricant (il consumption, las tan uecrion system Injeton pump Flange mounted neve holder, MPa (SI Nozzle opening pressure: Crab mounted nozae hole, se "nionae Holder Combination” Page 17F ELECTRICAL system Srtng Motor cGEs3101 oyle-Diee Engines La 18:1 (except 0-208 and OT-402) 18: (0288 and DT -402) 22-24 (313-341) 12 eee eee 0.20 me (O12 in} 907-056 (104"-200"F) 1535 mm 25 in of water 303-414 (64-60), sin, 90 (128) 08 “Operators Marval” TH he ober Bosch Rotary 20-21 (2085-3000) “Boss” 4-288 1av=388 1ava5a BVA 2aV—abA Bos" 12 Vk (4 HP) 28.V ak (53 HP) 24 V 48H (68 HP)CCrankcase Pressure and Blow-by Chart ‘ex. Gankoser rare Max, Permisible Blow By Engine | (igh eo Load) Se a | a enaie Tanga AT mem Hon HO ce fu. ff) | eum fe. Fsbo) veo | 40 ¢ 352) 20 { 708) pass | | tS |zso0 | 15 (530) 235 | 860) Te [tio | 8 8am 01708) cuales 2500 | 18 (30) 25 | 80) fai00 | 15 (8307 25 180) pans | st | 20 |os00 | 15 (530), 30 (1060 *oao | si | 20 [200] 15 ( 530) 25 | 68.0) p79 | 114 45 [2200 | 18 ( 530) 25 1 B80) prase] 152 | ao _|2s00 | 20708) 35 11230) aaa 2500 | 20 708) 30 (1060) ae | st | 29 [aco | 20 700 35 11230) 700 | 20 708) 30 10801 pass | st | 20 J220] 15 (530) 35 (1230), 2300 | 20 ¢ 708), 35 11230), fi 72800 | 20°( 708) 35 1230) pare | 6 | 28 | 3000 | 20 ( 708) 40 W419) 2200 | 18 530) 30 (1080), pase | 27 | §° {3000 | _ 20 ( 708) 0 1410) vr68] 105 2200 | 40 (1410) 60 12.0) Prose] 105 [85 [2500] 40 810) 60 120) rae ge [200 | 201 708) 30 1080) 2] ee 2500 | _ 20 ( 708) 30 11080), “Wh rectangular top rng "Wh fal Keystone top ng NOTE: Refer to "Checks for tating procedure and prope too, ‘Pressure readings obtalned must not be use a the man source of eng coneiton ‘i consumption eran cata must aso be used Ifthe peste readings af beyond ‘the specified Tints. Neither changes in oll consumption wends nor exankeare ‘hat some problem exist IMPORTANT caEs3104 staan 2 specie component problem But fe ony indleatore‘Static Timing (Degrees BTDC) * Bas Baas T= Doe i — DT — 358 ss. = 05,5 7 [500 7 16208, 173A, Tyg lass. a frs90 A [wea VIE [oe tga sai, bai, eT | Ivrea Series oa i Acco 1820with Ty isu. 6a W308, Galan Ge 16 foe Tee [a soa Ha Bee [16 [Gaon 102 Grader [16 fasa [a aan zm] Ibu=20. 16 sss legersou-tand [16 IW=60 16 sooorssoow.a—b ie] [amas BH] seses S00ATE [og ragrzs0 Toe P12") [aus eo] [ur Da 49,7485 16] [5208 a} [toss is 555. Tae} feats. 16] [si ie] [i218 18] ass. 1a] [sza0. 12) [ro-8cA | frsse is sooo, ve] [aeoasestsu, [va] [ase Te] fesse ci WstGOMsHS [14] [xooacoss Tre] brow 16) ee6-HS oer) —| 16 laste o/us. [ia] [eras 4 004/005, 16 ss SU 1a] (25006. wz 3080 16 [aaa 20a a B=3i0, BI6. 16 Isu-east0 [1a] lon |" | oaeaioo en [16] fore, 686 Res] 16, leas GOS [14 | js.u.et@-AB. | y, | loszzoonem) [10] |s-aas-t0 [16 avons ECL 14 | |s-w0. ic va famoAGD/S. [ia] fsao08SM, ve | (785: 10 acoA Gos [a] |usirc oss: 12 irigation = Unie [14] fase TE) [431,55 is sD, 12 [ade 12 250 A, Sa 12] [0-20 6 B= 25 eoatesMms [16] [o—Te00c 18 lseae58. 6x4 [17] [irgston une [16] fororez7ns [16 a 1a] [500 AHS aa] jrisr. 10 foreea 2] fasrens. 13] |eader Hany foo. 32| SoAusTiC [14] [tesc z aa 12 06. 7a larec ors [12] (3520 1a F006 sere it [10 000 FL ia saa iz [71s Comb 2 TO-68 10 [782 Cotton Fistor [16 fio, 6 10 a8 10 sa 2 lear @) [icigoton= One [16 [saa wecay [12 leo 301 [16 [sao (oT = s38)—[ 20 Dra ibe, 85 HO [16 [asa Hs 963.G0 [16 1265 ie 590 AST 16 ccess101SPECIAL SERVICE TOOLS REQUIRED AGRICULTURAL + | constRucrion | _ TRUCK ‘TOOL DESCRIPTION EQUIPMENT (res) | equiPmenT | EQUIPMENT Peston Ring Drop Fixture ones ‘wea | purer 3562208 Camshaft caring Removerinstallo Set o.101 ton | Purses ~ ENGINE TOOL KIT. = Pursit = ac sa tals tol onie2 roa | PLrsita = Irstaing oo spacers oeue21 1990] PLTSit2 = Injection nozzle sete puley Presta’ foal’ | per auety = Engin vave guide aver oeizs ria} | Pereira z Cylinder need oft wrench oeriz6 nig) | PrTsits 5 (hiner head spec bole wrench oenzs = niga) | pLTsite = Front engin sel installer oertz7 = aa | pLTei7 = Cylinder Daal Brith otis rao) | pitsara seaaiea Votve Guide Cutar oss (048) . = Noxal Sieve laser os1e2 148.2) | pirsioz 5 Valve Spring Comprstor os.462 (302) = sees Piston Rng Compressor otaee2 woe |= e610 Oytnde Ride Reamer ose7 vas) = 51405 Cringe Hone 0-408 (ase) s se1s74 Valve Guise Ramee otae1 area | Purses 5 Pressuteracuum Compound Gauoe ats ua | puresss 5 Ne Connector war (270) | purecsse - Hoe Aetbiy 14233a (zal | pLTa6s.20) - 0" Ring nd Poking Too! uas73 (srs) | pur-t08 - Pressure Suber 4046. (ota) | purscos - ‘Theemomel anc! 196 (38) ss1is1 (nts) | purtter 5 ‘Thermomel Pane °C 2007) ws1isa (1182) | puTt189 5 Dis Inetor 186741 tray | eersoz - Valve Spring Teste 15203 (asa) | PLr-to9 5 Comeresion Teter 15131 aay | eurstes = Compresion Teter Adoter 15142 (142) | pursz02 ‘Neve cup nat snd 3066 046 81 nd 3.056 046 At Coppa sting wither Teno rieie2 Diese! Timing and Tachometer Kit 153005 (3005) | PLT301 se2sze Nozala Teter 15714 on | etrse0 ‘se-2002 Noszl Tube Asambly 1724 (2a) | pcrseos 36200613, Adapter 15722 (722) | eLrseo2 362757 oe erably 15723, (723) | pLracta és * (FES) refers to old numbering sytem ccesa104{ SPECIAL SERVICE TOOLS REQUIRED AGRICULTURAL + | consrauerion | _ Tauck ‘TOOL DESCRIPTION EQUIPMENT (es) | EquirMeNT | equIpMEWT uel ator with ings and owes 16:136, ‘1961 - - Fue! Divering Kit 13a - Injetion Pipe Assay (For use. on D229 Engin) were240 aaa] — 5 los ne Tove Kit se20 120) - . Engine Stand 17528, 32 | pura Engine Aching Pate sat gaan) | puTsio2 Nozale sleeve puller adapter (Use with lide hammer with 518". 18a | 172612 (2612) | PLTSoD:15 Universal Wet Slave Pile 222 (222) | pursoz3 862596 lection Nozze Pale ose ao) | PLr3s0 = Injection Purp Kit (lneluge: a Pur9s7 — otaig thetre osama = qannay | pcrasza = Dee puller ositta2 (unt) | pLras72 S CCombiatan metric wrench ~~ PLT 3873 S Datvery aie gta ramover ositra cnr | pLTasra = Timing window osits = (11) | PLraErs = Banjo fing osits cite) | petasre z Sm Allon wrench S purae7? SI ‘Contr plunger sping pre toas toot cera ania | perasr8 = ‘Nozale Orica Caring Nese Kit 05.131 aay | purses e220 SAE Tet Nose 05-137-20 (19720) | pLT-764 ~ “CR” Injection Pump Kit lnlase: 15-508 (sour | putas a “Timing window adopter 5.50618 GOF-tA)| PLT-I564 = rovers po capt pate o5s0¢2 © (604) | PLTIEE2 = ator retainer o5-s0¢3 (04) | PLTISGR ‘Alignment 001 osso44 gota} | eLT-ase4 = ‘Shattael protector v5s08s 6045) | PLTaseS : ‘Slide hart 05086 Bose) | PLTaso6 S Ble too (ss) w5so07 wos) | Purse? = Ble too (ah ossos3 ota) | erases = ole Aseambly retainer ossos9 ——(g040) | PLr-asee = site bom ossoe-10 (50810) | PLTaset0 2 ‘Timing window = eras = (Contra lange sume) soi soaans | ecT-a66-11 - Countuore Toot (rca: S PLT, 2 ‘Driver Unit, handle sd toot bite 5 yozosssao1 | sess ‘Adsper pte 5 1070 554 RY seziay ‘ool olser : 1020 586 Rt = eet bit) S 1020 561 = DeEtn Gauge rot neu in Kit = 1020560 R01 | se2sis Crankshaft Slonce Weight Socket Adsoter 06515 - CGrankeat Presure Orfn Resvctor 135936 purses = Crankeat Presue Oil Restor 135935, 7554 = * (FES) refers to old umbriog ester GES 310-1 ‘PRINTED IN UNITED STATES OF AMERICASPECIAL NUT AND BOLT TORQUE DATA NOTE: Tore wr ain Neo Nen ant ve — at nt fat cn where peandces | am | ame | por | aw | aw | Fea eetia th si | Sap | See | ste | Sem | See “Bac egies oom ble =P | a|—-|« “oda wiht lane bla e}—| m fu}—| x “unin varingcn mctatdommbats 109 = | ao | oo | te | so | so | at “vin ton capo bl 28 wo || ss | 2 | | 10 “Msn evn itch carb 129 wo} a) mw || oo) om “as nn pith mets 103 wf) iw ||| so “comming rad = a fwl|—| o tect srnatinrsamentorcmeinasng | 90 | oo | oa | me fia | a8 sider urate down bolt off —| 2 [Pa] “Mor rar teh camer bot so | 7 | 2 | 2 | | 7 "Fiywhea ole ao} eo | ws | 90 | so | tor Bolts, seal ring retainer, rear se | — w fo = 4 “ovine mt ola | w|aojo| = “oyna tae —{—-| «© |— “ “ovina re wit water wf] om | ojo) “ovinder dep re th ale wf) w |x] | iw ever ra te —|-| = |—|-| 2» "Valve lover bracket stud nuts _ — | 6 —-|— 48 ‘ae sere ~ clang movement ~|-| a }-|—| 2 ‘Vale over brisket claoing sro || on |] | ene fs ener ~|—| » |=|—] nn eter anew kn ~| =| 2 |=] =| coe oper gupe | =| sso | | — Jn on Teeter ut w= | =| weno | - Mes 15 Est ile ss = » |—|—| = xt mod ad —|—| « }— 2 Noni hetero —{—| «6 |— 2 Noelia ats Food | st | iy lua} — | ene ere ron rt -|—| » |- 2 (08 Represent pound nch * Oil while mounting, "No longr uid in production. 1D Aer pretorgue ten adtional wo adgeor 120%, caesa101 ‘equ Hoking compound white maunting (Loctite #271),‘SPECIAL NUT AND BOLT TORQUE DATA — Continued em ee Paste oat oer wieesondincee [te | bea | Ew] ae] a] send tite | Say_| Seo | sum | Son | Sen [Nozzle union nut Nozzle Holder 6 _ “6 Vat cove sms eee oncom et 3 wait Van con oe ° aie Opin we ae . «l_l_la (porn open ue ~ w | —|— | eto po abo * 2 |ul|—| = atop cnr ti on ‘ 0 ese] — | cow eres poceh = e|-|~| « terve econ a || eal oO aw reve (S17 ad SE) ~ 2 —|.« pete ge pn - 2 2 Terochre Vcanp ~ @ =| Serpe Arle tor VE ton pe) : ° — | one (0 Ropetets poundineh, ‘Ue ligudfockng compound while mounting (Loctite #271), "No longer uted in production, Se Sates OF amenioa10 IDENTIFICATION OF DIFFERENT BOLTS. ius. A = Shatt diameter B= Stameing on ott hast AX Different shat ciometer Nain bearing bots, peed don oa mn = Nain bering bots plch ameter 127 mma Balan weight bls, ackedaown 5mm Balance weight bots pte samate 102 m= alr gear bat, necked. oun 98mm= lr gat Salt, sith iometer namm= 18~ itferne stamping on bolt head, 29, 10K, 12K, 109, 128.0ra ci cult stamping on er grr piten damatr bot Note:-Some bolts resi © speci shot pesning teat Where laa manufacture oF special tol is eoummen: ment atthe engine asemy tne tis important, there dad, datas are shown In the eapetive stone of ts {ote 10 ue nly the specifi Dots comply withowe mara aafiy sana, SPECIAL TOOLS “Intrnatons Dial engines are dena so tat few Fics tool Kit However, when the us of Inexpensive feels tole will Yaclitata work, auch esulpmant Imenice in hie manus, coEss104VALVE LEVER ASSEMBLY st General “The vale lever astebly reeves its lubrication through theholiow valve ever sett Oi holes are providedin he ‘ave lever shat (5) vt. 8 to ibriete nil vale ‘wth the respective ctway inthe racket. The ark (3) Tut @ must be Inline with the camping slot ofthe front bracket. Replassbe ll plugs (2 ust 4 are ‘od to low up bath ands af theshate Vat levers fr inte an exhaur valve itor in length but we providoa with the tame vepaceble Sushingt ‘nih matt be rare oe fer ntti, or sunliag with bushing in place, Specifications Removal and Disassembly “Thoreughy clean th Femove nut rom st lat ani the somos Slamping bots (2) and pas in bracket sgh tars the senor taking eae they do not de ot the sak (rer the floor Side a pers off the shee an place ‘hen on 2 tle fy renou! rder to feitate coves, 1 = Sw nats 2— Clamping bots 3 — Becht front 4 Bracke oar In brackets) mex, prmisibe wea before racantonng Valve lever shat ie Raduton contact end (2) Must. 8 Hardness on edhe Depth of hans Soxing (12) ue. &, Fre loge Test lonath 21.889-21.668 mm = 250-809 (0.03 m= 0012" outa oun) 21818-21640 mm = 851-252" {0.03 mm = 0612" aut of oun 0022-0062 mm» 9009-0025 2.10 mm = 50" 0.8 mn = 021 D7 m= 18 25i0 m= 1.00" 2anl= 3 kg 8b caesst04.2 Cleaning, Inspection and Repair With compressed ar Be sore aol pssges are ee from stage ara seine Chek wate Iovr shat, eve buthiogs, trust washers, nd toacer rings Chick busing ang vave Iver aft for seorng an out town wear and replete fry. Us 9 mia sf punch and press plate and Install na bushing (2h Tew busing must be fh wits te two ate fees) ls 8. Uses 3mm 1" {io opan the ob paeege inthe buting a ove chips and burs en hp busing tot, abe "Specieson” Valve Lever ing atthe snd (2) which contact the vahes, Remove ‘nly enoogh material to give an even face onthe end of the vae lever ana take ear thet the rouning ls mar tained langtaye to ater ptt ane ation on the ne withthe valve fever shat in th aa plane a ths would place side thst an the wala am, thereby fusing ot otroend west om he valve ies ‘hen reconditioning contact nd 3 2} Use pecareteing machine. 8) Maina specie acts. 6) Be are dept nf Rants Ie wfcont aftr re: st. 6 4 Oltpasoae, Imma = 1780 8 — Vale eduting sre here eppropiete grinding faites fr valve levers are ‘nt svalabe es advisable to instal new ake vere Inepect contact face ofthe ve adistng srew (6) for Adjusting Screw Cheek and epics damaged srews with ne on SHAFT Cheek for outotvound, epee 3 wom shaft with = NOTE: New design rockers thats ar Deep Nive {rested so thatthe surface il be dl, ret gay In Spvenance, rather than te atar design ington fr lesage and vepice plug, I nesesry, ung Ug sealers Check vavo Wer springs epinst speestions {nd replace with new ane If ne of coraion, chang br faigoe bein to show Valve Housing Cover st 7 1= Valve housing corr 2— Endnotes 3 Gauge bre 4 Leveling pate 5 Messing point Place the valve housing cover on lvling pt, Mat, 7 [heck the cover eontacte Sars (3 on four pas. Age Upto 5 mm= 02" atone sont ieparmiible, Check ‘the heght on both cover end st measuring points A ‘ifrence vp to 1 mm = 08" fe pease, Check ‘alve Reng cover ale or cracks nd other dere, If eracked orf warpageencead bove Finis, epic. coess10-4Reassembly and Installation tho Figuce of st. @ snow sequen of reset mily Rentsombie the valve lever shaft in accrcance with Ist 8 sommencing with font bracket (2) OV all 4 Champingste ch mark (3 Hust 9 of ee shat must in tin clamp) sot (4). Be sure the sha end ah with bracet (2) Thi wl esate ato asap mn rect tnd shat coreone ‘Tighten eemping bolt (6) Hay to sete thie aur car to sree nck a evnevt ve ve 13 ‘Spacer rng ar neal on ster side of every inner valve levee sete bracket and onthe Innerside of the Front bracket (1) Mus. 2, There ino sbacer ring Deven the reer Braket and the adjcint vale lve. 203 6 2 or. 98 1 = Bracket, front vate lve (short) take valve leering) 6 Srng ‘A Mx. 1.2 me (0.047 in} deviation of Sings (6), located between each valve lever pai, ha ‘throm wathers on both see Take cara to ar ian exhiut vale Ives, Side the ely on ‘ad (2 at, 10 ‘us. 10 Removal or instalation of valve shat aeambly ove shaft racket Claming batt Tighten stud nuts and clamp bots to sped tore Check dimension “A ust, $3) and edt vale ces 3104CAMSHAFT, IDLER GEAR, TAPPETS and PUSH RODS General ‘The canshat (19) lust 11 lend the injetion pure) a ivan from the front ed of te ranks hough 8 tain of gears. Al gers are punchmerked to eure comet tuning. ‘The camshats sypportd in bushirgs. End flat is contlld by thrust pats (20). Th dive sor (21 i hayed ard ah toe cial od ‘The camshaft bushings ar pressure lubricated from the ol gary and have led Hoes. se 19 ‘Specifications {In brackots |) maximum permite wear before reconditioning. ‘Camshat, Di (Early type 20.0-31.0mm= 1.14122" (Camshaft, Da(Curent ype) 30.0820 mm= 118-126" (Cam obe wth (Ear ype) 220mm= 87" (Cam oe wits (Caron 8) 28.0 mm = 102" (Cam ope ite 1808-813 m= 917-320" Com tobe ie 8058.18 men (317~320") Jourals, Dia '8,00-57.97 rm =2.2095-2.2828" (09 mm = 0012" Busines, Die '58.054~58 024 mm = 2866~2,884" [0.03 mm outoleours) Camshaft running cleance in bushicgs ‘0024 0.088 mm = 0010-0033 (+ 8.3 nm = OO12") (Comhat ond float 010 = 048 m= 004 ~ O18 (Gee (20) se 19 Bore, Oia (41.27-41.300 mm = 1.6280— 1,250" Gor sat Dio 41339-41317 mm = 1.627 —1.5260" Becki, Drive Gear 21 er Gear 0) (008 = 027 mm= 0035-0108" (+ 0:3 nm= 012") tee Gear (20) Bore, Ola 2,098-42.072 me = 1,8580~1.8542" ‘Runaing, clearance ‘0010= 0.040 m= 0004 016" End toa. (020 = 0.33 m= 008 — 013" ‘Becklash ler Gas / Crees Gear 0.18 = 0.38 mm= 007 = 016 “+ 0:3mm=012") {alr guar eater, Diz 95000-34860 mm = 1.3779-1.3775, YYaveTapoets (18) Oa 19970-19985.mm= 7865~ 7088" (0,63 mem = 0012") Bore in rankcase 19997~20030 m= 7873~ 7885" (005 mm = 0020") Effective lat 48,100-47.700 nm = 18037113779" (0.10 mm = 008 ") (lesan in eankone ‘0.012 0.060. = 9004 0023" (+ 0108 mm = 003 ") Push Rods (17) Effective ongth, 0-155, 0.208 and D310 177.90-176.50 mm = 6968-6240" ( 040 min =.016") (04170. 0.730, DT-239, 0246, D388, and DT-388 211.50—211.00 mm =8:326-8.207” |. OAD mm ~ 218"), i268 and DT 21700-21650 mm = B'SA3-6524" (O40 mm=.016") ‘Thrust ite (20) ‘Thicenes 701-896 mm= 276-274" Bore, Dia 48.2 mm= 1770 (peso) Bore, Dis {462 mm= 1.740" apace) aires ates oF aeninRomoval and Disassembly ote 1 Beto camshat remove check 2} Sictah of comshat dre gear 3) Carat end teat 8) Camila it Cam abe tit may be checked by maar of i insice Fest the sys f thet nestor om ane ofthe push rod Rotate the engine ons rvolton and aot io indice tor mading. Comeare reading with "Spectzstine” Remove vive housing cover, ‘nd ernkeas front soe Tie sat uh vous row, 13 1 Somuhet ve gror 3 - tar gor 2 Apert, ‘47 lar gar bot, Le teed 15 (Check backas, runing clearence an nd loa of eer ‘"() lust 13ers enor ie Ferpove bot it) (LH trend with wae. Take off ler sr with nade bearing and Hut in to. 16 22 Aperure Femeve ir gsr cari {1 lust, 14 Remove cuatt thar pt resin: bots. Tha can tnsesched trough epee (2 emo crankeee ie cover, Hala tppet in thar toppoeiion, using a uber bard fr ten enging on tide open up, Caretuty pall out cemahat (1) Ili 15 and verove ‘appa (2 Fracesery pret oft cast ie gow, taking cre not wo damage the ve ot for he tchomatr, cses3t0416 Cleaning, inspction and Repair Comahoft bushings mutt beta with have To be Aah with sudfocer Front face (i holes in all corshott bushings most Vater gace line up with ol eles in ronkecre belt hole Section A-A, Cente reamer in bushing at pear ao posible, Bushings must be in alignment fa bor 305 inch de Tow Bove imi wal enter fosly ae, 16 IE the camihaf bushings need to be replaced, team Dock and replete old bing with hing a ton in 1 canna Bearing-Drver, “Ta flowing fin boring equipment or ite equivalents require to tne bre the emer bushings, Kwietoy or Model Le 2000, Lerpas | Meets 2600 ‘AME — han, 17 BERCO alin a, 1 = ter onc cari etsning bot en 20 lelergar ear GSESIION neaNote: The ile gsr ere 2} with vtaring bol (1) true urihed 6 chow ins, 17 to te machine 5.785 dep eriaeg eras se. 19 ‘checking aus hack for the spect adie 146,787 146 858 mm = 5.790 ~ 57810"l s lllows: eaniairlttt a nnout 2) on alt of house dame of th er tear at anon Patt ving br dane Wan te eine back posionad onthe wie of he m= tervo te iptedradie. Ung on sie ero. thi nln oe thes tasting on es Inet, eka own is 1. Gf tn borg bart palonhebocr soa at oes: —b) thera om nt tal win section, the feed 0538 mm = 001" rumaut om Font 9 rea toring br mun rene wae ff wi ios 18 > ipctieatone on bam end (1, Is 20. |= Boring bar heads With the camsheft gear end dlr eisai check fer proper ger backlash, st "Sseceton mw SESS or anna18 Comsat 98299 of _.__| Point of esnoment 0 determine comico wes Inspect cam lobes for weoe, Compare with anew can shaft, new carafe she vali, se 9 microme. ter and taka» vening scrote "AWC Ilva 23 and Sect ip "BD" This wil ge the car lab if, Roar to "Spector Inspect cams jours for wes, raf to "Specia Repos the carat fear sence, (Camshaft Geor, Trust Plate and Idler Gear epics the carat sar andthe ler geri et baok- las os chckad pie to removal sot within oad Inspect the tot of tee gas lo for ining ack sd burs Replace dara ges. ‘Check the onion ofthe thas pli, Rafer 1 “Spec: ove once replete tus pet, Peplae camshaft gar flows Inca the thrust late on the and ofthc od Inet the Weedotfekey. Hest the coma ger bproximaty 400°F (2600C), all an the sate ‘withthe timing marks pointing outward and pes ash 4 wi comet fan Important: so FES 1181 Tharmomalt Stk to dete ‘ine the tamperatre, Mark the ston 0 Be hese ‘The mark wil apear dul and chy, When the desired temperature facia, the mark wil alt an bears ‘alosy gu. Do rat be concerned with 9 change ie or ‘st, 22 ng journal 3~ brit punch Ik may te raceary to pret the gue into its progr poiion onthe shat. ote: The thru plate ceerance should te set to £2088 m1 (00857 white the gars lo, Mae 22 (440 mm (0173 ‘ler Gear Carrier and Needle Besrings st. 23 1 ~ le guar carier 2 lalergest 35 Needle baring 4 Thrustwather 5 Noskaddown bot (sees) 6 =.Spacer reg ccesst01 RNGTED MLURITED STATES OF AMERICAAepiae pets (1) lt, 23, it running clearance and oF end at ofthe ger io hacked rit to oval is Feplace neele berogs (2) at ¢ st only. Replace eckson bot (3) with ta ne ich aire bol {Ls tre Volve Tappets Inspec the appetsapinst “Spacitiatons” an replae shy worn epg or srtene tots Push Rods tespect va *Sposiication’ Replace Aassumbly and Installation ty 24 trstall te crankcase se caver an tighten the bot to species toque, ue. 26 10 ts, 25 2— Necdie beerings 3 Spacer Install pars (1-3) ae town in ist, 25, Lubricate reste Beton (2. st. 26 ben nealing the isle grr ras sce the sing marks ot the ger in ae i, Tost. 26 Goat te tveads of he ler ger Bt wih lotto Nov tor 27% Install tho heist washor an tighten to pei ore, [Check slr sar nd ply. CGESSION onnus 27 Gear ra a ring marks 1 the injection goin i nao te ftoaing rast Se been ‘The inection pun dre ser uss for mre than one nine ano caren nore of ing marks. nbered from 106, Must 27 Forcsailratrt ilst 431 an respective chor. CAMSHAFT DESIGN CHANGE Description ‘Tae coment forall Nous engines hore ben ebanged as follows 1. Tha cam lobe width ofall 3, 4 one 6 ytinde engine amas ha been Increased or 22 to 28 mm (7 t0 1.02 nes 2, The camhattdirmeter of all 3, 4 and 6 cylinder Cngner at bean irene’ from 31m to 3B rm 11.22 to 150 nen in the sea between the Bearing Teural andthe intake ear be 2. stm aang journal of 4 elinder engine cama: 4 The bearing journal of 6 einer engine eamshats Tve bee vad in umber rom 7 #08 journals. 5. Sovndercamshate romain a journals Land bronze camshaft besrng bushings have replaced fi syle thn babi besrng for engines. Service Instruction NOTE: Retero Grankease Section fr ations service 1. New tend bronze bearings must be used with new vo camanats 2, Dinlaced typ tin bbb bering te to be used on 2 cylinder engines of 4 sna 6 eylindst cankeset ‘onuipped with deplaed type comshat DISPLACED 4 CYLINDER CAMSHAFT WITH FIVE JOURNALS ‘emica a NOW GENDER CAMSHAFT WITH THREE JOURNALS coco aotiergatoc; on) [NEW 6 CYLINDER CAMSHAFT WITH FOUR JOURNALS, i. 270 Camsbatt Design Change caesa1013. A ciples type camshaft may not Be ueed ins naw ‘yo eankeas. 4. When Insaling 2 new type camhaft in» lplaced yl crankeee, remove old tye Un bobbi Beane, Before instating new type catshat, he oll bores of the fee Journals must be closed with plugs (TH Port No, 3-228 862 Ri) to maintain ol presue at r> Ianing bearing. These plas re tobe installed fo the loner camstete bearing ea al bae CYLINDER HEAD, VALVES AND VALVE GUIDES General Cron deposits and wear on vaes, vale sate and ‘guide ae nomalatectr of fi! combuition, xensie deporte and wear however rion engine ffeoney, Moreover tho eylind head may slr foe damage and warpage dos to Imoroper torque of bet. ‘Values an thir condition area Key fctr in obtaining proper comeeion Cylinder heads of atually sapiated engines (NA fines) are fwed with vale set ire for exhaurt vate 21 Cytindsr haste of turbochargd engine at ited with valve seat inserts for both intake and onhauit volves ‘The vave sat inserts cn be apace If nace, For this purpowe vv seat inserts of two oversize and respective euting tool sembly ae ave ‘Specifications (Peer to us. 28) (Cylinder head (1) mm Gch) as oss (3.8902) ct east (3.9098), Min, perio thier han feaing face het been rework 9884 (28798) Wiarpage on ealiog surf, mx 0.12 (00087) Nozzle ip 25 (a0 Protrusion 3 a8 1 Oylinder hess 2— Gasket, rater to tat. 69 2 (Nanas holder sleee 4 *Adaptr 15 Stud, vo tover shot bracket 8 Stud, exhaust manifat 7 Stud, coolant manifold 8 Seat ins naka vae 2— Up 10> Upiug 11 = "coon et 12 ake srnglock 13 Valve spring retiar cap 14— "ae spring 15 Vale stem oa 16 “Rotocan 17 Vane stem guide 10— Intake vave 19 "Exhnievave 20 Seat inert exhaust wave 21 Sealcng 22~ Plog 25/24 — Uttng ever “*Equpmont of cylinder head depends on enplstion seforta Parts Catalog, ust 28 Cylinder nea for turbocharged eines oGEs-310-1 PRIETED IM UNITED STATES OF AMERICA2 ‘Valve spring (14) 31360007 305608087 Iya spot) (wed or green sp Free loath, wm G2568 553 foeh 206219 2.18, “Test onthe mn 94.2 342 inch 1.36 134 Tewtiood ig 6076 ee72 fe 152168 1465-1607 NOTE: Before testing now vale spring, lod tall the ay to boeking eit, 3 7 ts. 29 ‘varia vv tet insrt counerbore chart Tieua Caantaior Di Trae Ss room fight | UH ae 29 O18 (ous; | sais eso) | aaa (sea onie | Fa7__‘(a060a) | W228 _ir86001 wa0 (ote | 240 (nss02) | azay—(.6720) connie | azaz__(ravo0) | waa _ thera) Intake Countarbare Di “2h that, 20. 15 (o08r wae (7s0e) | aaze (pao aegoe_cryaoer | azn Th7aT7h a0 (oie | aaa (17001 | axa 1.7500, cvonine | tease H70zr | TaD TA TEIGH 3. 12:24 mm 10482) 1229 mm {0488} 4 5mm (0020) jg) 9.7mm TOa26t CCounteoove di) and (2) let, 29 mur beat ht ‘nant and concur tothe vave gue bare maha {O10 re 0.008 nen TLR ‘cGES 310423 or, 298 1 take vas 8 Rotocen 2 Exiauityahe 7 Vai rina retainer cup 3 — Vat ering 1 Vahe ering locke 3 Vote sem guide 5 Vahe on set 10 Coctane et ‘5A — Value seat insert, ntn Tturbochoged ong ony) Valve Timing Intake opans~ degres before TOC we Intake loss ~ dares cher BDC nha Exhaust opens ~ cegresbefore BOG 6 Exhaust closes ~ dees after TOC 0 Valve Dimansonal Chart, ust. 298 Tie Tae a ee TR Dison tron tates oft ofndarhaTowte | 40-30] oo or] 12-30] One evel thevove a Tine te ono |g ae we ae Tae] os] BORE | wa D.__Nalve stem diameter 9.965 0.3924 g9e5 | 0.39015, Tas] vase iaa——] s08 AC 830 ves |aio | iste veow—[osias~ | reos | onsea rece 16078 0.6330 16.078 0.6330 H. Valve guide ID (after reaming) ia Seen * a toa | taeee [toe | oases Vave guide 10 (sore arin eae— [osma— | sae— | oame— eo0>—Y oaeo~ |ye0s— | oan ‘ave stom ai bore in rndr end teao— | ona [taan— | same Sa fase [ara fsa] sae a fier | Sea fear | bose Timm va vn Soa WT Te woes 8 oa Taxi sonata Gees "i _before reconditioning (valve play) ons 0.008 O48 0.006 “ake ce angle bvaen a and Donon oT ‘valve head, degrees 816 seu 1e "a sat ag in GTO Ra ao % = Tiina sonabe ery ae etbes tov ad Sor ox0__| ocr | 010 | 004 eae ovale ue bow on] oncte oa | ocoon Taina owe 12 [aoa [42 —[-o0oa? Wa reward 020 oo | 00 | 002 caEsaict24 Removal and Disassombly ‘The evlloder head can be rmeoued without removing injesion note intake: exhaurt-and water manifold Howover, eaten le neseary when coring intake ander bores 1 ses posible to remove the eylnder had without femoring the vale lever stem, Ht the oylinder hes [Sremoved without rrmoving te noe holders, t must nore ts. When he engine is overhauled however, it I recom: Inanded thot above menioned componans ba removed por to taking the cylinder esd of so hat he oti fad ean be propa cleaned and nipect Clean the engine exterly. Mark dszembled ports, Such ay valves valve stor guder and springs and ploce them on tae in removal ode to Teltatressiemby. st 20 1— Atternator 2 Injector pipes 3 Nowatolders 44 return ne 5 Intake manfola (nthe lft hae engine sid move component (1) 2 (6) ot 30 Pug all openings of injection pume,inetion pas, fst line and nazele holder to proven etry of it into the fuel syst. Mast 31 Exhaust mani 43 Valve housing cover (nthe sight hand ein sid remove components (1 0 ia) 31 Process olows Vio. 32 1 — Vat tne aha bracken 2 Stat 3 Glampinabots Rerave vale lever aso, st. 2. st 39 “Toke outvaue push rods ust. 38, 10-4 aes. PAINTED MLUMITRDBTATES OF aMunICATt 96 Lotte einer hea tls evenly and sternal ater checking torque vale MOTE: To avd warp do nex remove eylinder Need Une the engine hes cooled down Lift off etinder nad sing engine ting eye, at 38 To remore valves compres vale wring with compre: sor tol and tate out ping etait looks, st. 35 Cleaning, Inspection and Repair Clean cylinder head thorounhy Femove carbon deposits ‘fom th bottom of the cy Inder nen and out of exhaut vale pert MOTE: Moke sire water pauses a1 tee of obstue Ieepect liner ea (noucing nazi» bowie est teal for hair ertekt, ung modem raving methods, Mast, 26, 2B g nus. 36 race check hs, 27 Inspect the ovlinder heed (and the erankss) for war fs, if engines ben ran wit 9 Slown hase gp fa. 27 tu. 98 ‘checking pattern, cyinr head an crankcase 1 move than 2 012 sam {07 inh) flr snug ean be entered undsr the sighing, the Rest fot he ‘Pankesee) may be reworkat! to te up an posse ‘worse ditrtion NOTE: Crsekthec/ndsr bat height for renorking Do not stace the ass, if te minimm alow able "reonditoned heh ie below spied Replace dort erche hess. cses310426 leakage i supoctes in th water act ofthe linger the ap eankene, make the flowing tet ows evr ase with aves and nozee Bung On Crenkesse. Remon il an, evankess front eve, nak Sod esnoust manifold and hermestt. Seal water intake port proary with a gasket ana st fb cor plats, Connect te Hote ofa etal pump {the conant manifold in place ofthe coonating hose Fur nwo sr premio 200 NPs (20 pi pote: {8 ang 2 tactoson inhibitor. Oheck for eakage tower Oving sf evlinder seve, coolnt pps, nore Ino e Eliminate ny posible aka, here tasting facie are arable, he tat can more tay be mde on block, The evinder bead must be Trounec onthe Dial in te eame manner af on the Caneese,. fr tis purpore the Block must be Tesh ‘nth 0.08 mn 002" tnt 39 earng vale resin wet) (inne esatson 30." 12") Innoact valor for wna, tut, 38, Ecosse wear will ‘ke for hard earting ane pal engine oeey. 2} nwa new values 1) nal neva saris (WA angine,xrsur nly) 1) Rework eying nea sing foe Before wor 4) Check whether the eylinder heed eight permits rework 1) Check to se IF nozzle tip proton wail remain within species Hints ter ework st 40 4 —haut va set insert 2 Welds ans To ramove va sat sets fst wel two opposite ag 12) Ie 400 provide pute op Oversize Valve Seat inserts eock counterbore in the eyliner head, refer 10 "Spectiestons™ ‘efor enlatsng the courerboe, be certain wave uldos ‘nde pilot of the spac euting tol ae order ‘Ci the new ave set iets to last 60% = 76 in ey ice before isaiton Ths proves metal sap- ing for the sid ofthe countrbore, nating full con thet of the ieart on the Bottom and ake ofthe coun tebe. Aneta nee srt ung an inset diver provide for hi purpoe Caution: When using exrbon donde sre adhere to Inervotons to voi injure, Do not touch dexp frozen rts wth bere hans, ces 3104 ‘PRINTED Md UNITED STATES OF AMERICAReconditioning Valve and Valve Seat YY 5, tus. 42 Vat Seat neat Anak vale fine) 427 #02 (1.80 0000) ‘A Exhoust vl neh) 407 £02 (160 0.008) 8 — Refer tout 20 Early design: 10mm (038 neh) (© Late design intake vale, 8.0 mn (0.38 nent exhaustvahe, 8.78 mm (034 inch) D~ Esty dean: 90° = Lave design: 15 B. A 2086-¥9 c i. 43 Insert Ring Property Inctaled [A= Valve insert sng 15 —Insrt must bo tight tt in counterbore (0 Bottom af inser ring must set squrely on bottom ‘of countebore, NOTE: De not int Inset dive, ints by hammering orsking “Th following procadue applies Yor etecing eat insets forfacing ew ines. carton, sale and oll before attamoting vale sts The grinding wel, when laced ait an oly sea, wil becom fouled ad ‘never gencing wl occur 2 OTE: Before insating he plot, be sre tt the vee ‘ules are pertecty clan and meat the onann socio ‘ons. This important otherwse, an eccenvc wat il beet. 2. Dress the nes tothe cree ang, Lightly ubriate and install he plot ote cornct ela thevave ‘ui bore, 3, Lower the atnder Head over he plot nan unt the {ra vety gently slow the whes! ta contact the ves Seat. Very ile presur otter thant normshweight (Of the whe! should be ua, ‘Sudden hae eure ‘in caus cocking of the plot inthe guide ane reat in eseansie grinding. Aaa the wheat Frequently ftom the valve wat to prevent evemeating Sad to Star away ending suse Grind the sat staniy 1 prone sn en smooth ste, Vai for intake ae exhaust ves ae iat Cec the set concatricy, roundness and wake face comact using Pusan bln. Spread an extemsiy ‘inf ofthis blue on the aa fee ond set tne vale ino Is guid. With pressure onthe act canter (ofthe wave Ret, makes quarter fur ottion inthe ‘2st. Remove th valve ana iapect the impresion made upon the sot by the wane of Bling, and Upon the va fee by the removal of bling The Vale seat should comer on thovahe fate and mst be oncersc with the bore ofthe wah de within ‘0900 — "0.10 mm (0.00 ~ 0:04 inch). Check several ties t guarantee that oo ror wes made I's ful seat wish contact around the one cr of stated vai ot shown, th ans donot matt ‘willhen ba nocesry tress he vate sat nding wheds, changing te ane icently to. cect theron “The correction should be made onthe ave sat not conthevaive, st 46 ‘Valve Sst Anges CSESSIO“ ca28 Ton. 40 Measuring Valve Seat Wath ths. «7 Grinding Valve Face with Rating Machine Insect valor for wes eine “Spucifistions”. Sern Uy reconditioning valves make sre eas margin and Concenicity we within specfenong, # not, us new ‘Ate refcing each va, iapuct ha end ofthe stmt ‘rear notional, reface the end ofthe stm. Grind {felony to uel the eed of the tom, Wear Parts a 48 3 Vale stem se 7 = Wate rring tse ooks (on maior engiag overhaul ie reommmended to rotace ‘he wasr ort (1) fo (7) It 48 (ceasonally, when bead hae bean striped dn napeetsbove pets and roles them a nace. Rane valve sem wal {3} whenever valves ave Been remored Valve Guices & aly a0 aa tae. 49 Use steep! brush orem arbon depots in the vie bore, ier, 4, Wass dow gues, wing eering Solvent. Blow out ll rbon vith comprssd. ar Position « lght atthe botom ofthe guide bore, 2d varie the walls or boring, cracking ard signs of Srcesve wna Check the inside meter of the guise bore at vrai points rounds creumerence and ong ite frat Spuctstions forthe guides ae shen in "Specieavons"- Replace any gudes corsigeed nsericable or thar appear close to a sviwable borer caesstoatt $0 Inatating Vat Guides 64 Value Guide Isai Toot A= 201mm v.72" B= 28mm= 107" use space too, Hust 60 and 81 to este corset ‘depth of guides i the etic hea. Ba sure he sep fo ofthe guide isp Check the tool tr dimanion Sn ind down ft ncaey st, 82 New valve quidos mus: be reamed to sz, ust. 52,386 "Speatestons Clean guides ater reaming, Lepping Ms 63 Lapping Ves Into Ths Sate Alter lpping, vate Toss and soste mut be prfetly {smooth and show oven marking, Be a6 10 let “saya seman of ringing compoure Again check the vie reson, Sen "AY and “8, I, ‘Nozzle Holder Steves 4% yw 1 8) adapt orem oie ne ue. 84 Femeving NozleSeve ‘Te injction orale sleeve can be eeplsoed without ‘enoving o" stasembling tha evinéer head 1 don this wey, Beaute engine eoolnt i drained below the ‘inde ea lvl Detove removing the sews, To remove the noztle sleeve use speci bolt (18 x & inch) PLTSOOTT (FES2512) ond tun it hte the eer. The Bolt il et is oom thrid int to at eeve. “Then stow sie hunmer wpter OTC12M (NB in. x 14 NC} ino the end ofthe Boland use te lide tammer t9 remove the novel dese, Hut, $4, Femove the sleoe from ts tel and dacerd Inspect the nozzle sleeve bore in the minder hen and bose fis ean ar ae of een, al scl or, ccessi0+2 Seating Thorournty Inataing osva Hote Sete with Specs Took tion, Must. $6. bottomed inthe Coolant Jet ‘To temave the coolants is good practice to ap the iad, soe arrow, Iie. 57 are poll out the et with sulabi sore. Always inspect et for proper water flow, ine nealing nea jets, ake care that seting faces (aro ae fl th th eye ese U-Pluge ros oft fae Com the ene sith Lost 1s leakage is apparent at she plus, reine the plug Inet ew luge wth 2 witable ot punch using Meat tcestant fig vesler, Plug mt aot rotude Fam ‘Salng surface ofthe cvinor he, FReassombly and Installation Test 56 tus, 69 Insaing Valve Str Seis 3 Rotecap or sbringesiner cup \Vinen installing valve em sel (2) Hust, $9 lst place the fetoco (3) on the valve aude, inert te ale and Side jomcer {1} over thevahe stp end. Intl the ee] fo that ew bottom an the stoped ae gue ‘Alter the new sl eine do not ramove te va, PrnreD in UnITED STATES OF AueTo fit vale soins proceed flows Win jumper (1 Must. 89 on she vale sem fe vale tpringe (3) Hs. 290 its retin cue) Using» sing compression tool depres orngs only far nought ise seing lone (8. Remove moor rom Valve stom an sping lok (8 ‘heck vale recasion "A and "8" aphnst "Specifies: 28 26mm (10-10) Cylinder Had 1. Clean the carbon from the pistons and be su festa surfer of the wankeste ana linge flean andy. 2, Be sue thee is no ol in the bottom cylinder hand bit holes to prvent hydraulic lak when the als sre torques. 23, Before instaing tho eller hua, check eyindor Seve proton, refer aust 2. fhe lave pro- trun isnot within specfeong, remove ha save land follow the complete procedure under Must. 78, 4. Installs new cylinder ead gakar Must 60 to the crankesie_Usi @ hoist nding, nove he oye Tron. 60 “Nom etorgue” of "ai end Gacet ‘A ~ \centiation charac rod paste beds ‘ound the water nd i sling acer, 65, Following the sequence given in eam Mus. 61,62 ‘83 haan the eylndr head Bets in the stops Refer to "Special nt ad bok tue dete" Never ‘os bolts with damaged of mered tends ae thee trend to show ehigh torque ead NOTE: Cylinder heads mounted ther with tu, bolts nth waters or with Hang Bot, sepensing on Year of manatee, at I bolts or ste must be ceplaces, donot mix: up pars, replae comptes set, se 8 wp 2 1 9 3 Oo BAB RB AB gees" aye aye g 8 ' 8 Ege, 3a8s =| OOOO, syiyiyiy? Se igiyis ust. 63 Torque Sequene for Cynder Hess 6. Follow the reszembly procedure as below, referring to the eepectnesectons of he manual where nese love shaft ana. Aaja vale lara Aspiae valve housing covet uing 2 new et Repiace manifold and thermostat, Instat turbocharger Instat isetin noel and nozzle hols. Fl the fun tank and vent he fa syst. Fin engine ot. Fi the coating system cGesa104Start ad run the engin at 3/4 rated engine sod With no load unt eperting temperature [2D ~ 65) [176"= 18BFI is roscned, cover the actor if feutiry, DO NOT run for over 15 minutes vir to Tetghaningeylinde ews bal. Retighten cylinder ead bot o specie toraut, to Tost 61, 82 oF 63 for equanes. When rstighteing head bat irttooen every ole 1/4 urn then dahon tospectedtorgue of 148 Nem (107 ID NOTE: 16 new cylinder hood geckst (with red plato Derderian angines equipped with studs and ety OH alte th round womnere tering torque I 148 Ne (107 WE, 8. Shack vee clearnetand readust at necasry, NOTE: When rtorasing evlinder head nuts or bolt Sniy howe alow sroper torque ae to be fetorqued 1 Specications The remshing nts of bolts complying ‘th orabore torguespecfntions must not be loosened Fetoraung evlinder heed aut of bottling tore “rtench and sped wrens Mist. 68, NOTE: Rateravng of yllor head bolts or nts in the fed ip sot oensary whan the new “Maltonence ‘fee oviner ad gasket It, 60 has been intl XW aut syle cylinder need gasket (without ed pati teal Is sg, sefigtan cylinder Head boll, et. at caes3101 rnereo we UNITED ETATEE OF AMERICAMANIFOLDS tJ INTAKE MANIFOLD st 6 reuz0 Romoval and Disassembly is 67 Removing instal intake manifout Remove inaction pipes and sir intake hos bor ve ‘moving the aka rani Mist, 67 CCloaning, Inspection and Repoie (lon the monfol and insoce for exes and istoion, Feplac the anol with ew one whenever tion Isimore than 0.4 mm = 016" per 250 min = 10" eng Iapet sir howe ar hos clams. Replace darraped parts, i a t tus. 8 General (Intake) er] “The inte manifold is wt in vague dios, dope 1 = Heating pine ing onthe arangeant of the leaner ston engine 27 Spade terinat type and appiation, lus. 6585866, Set Parte Cason 3 Alecieaer sie ineator conection Inspect the manifold for ght sain, whenaver anne overhaul is neces. cces31044 Check the contin at seo 44) Ms 6 8 teting velape of 10.5 V ond an amperage of 62 A {he coll mux glow brah Replaeadstectve heating ye 1 olows Heat up manifold ot 1s uiely pul Heat minifole to 2007 Be sure the new pie prs 5m (2.8796 fom the menial ts spe evn! 121 prope pstoned nd peor ol ands het et mem (08 EXHAUST MANIFOLD vs. 69 Exhaust manifold for downsnept 11 — Exhaust morte frome exhaust connection General (Exhaust) ‘Te exhaust manifold it used in vous dass depen ing on the postion of the mater andthe meen 0 tren the engine fetalled, or, 68. See Pars Catalog for spt variation ‘on sogine avenau remove te manifold so that i be eaned ang iipeeed Removal and Disassembly nus 70 1 Exhaust manifola 2 Water manitors 3 Valve housing cover Remove axhoutt pipe andor muti, Remove exhaust smonfla (Hust 70 Cleaning, Inspection and Repair Femowe carbon depo from the exhauet manifold A light accumulation of carbon doo will not affect engine operation, Inspect the manifold or sins of het corsion, warpage Replace an exceively coraded, warped or racked manifold with new one Insoec studs and nuts and elo if acer, Manifold Reassembly and Installation Instat meniols taking speci cae to ensure tht Aways nea guket whan nealing» mano. “Tighton stud nuts of bolt to spctied torque. Retghan fartonert after ansi hot and ain ater not ler Install any ijeton piping intake piping or exhaust ploingturbocharser that ware removed, cGES3104 PRWTED MLURITED STATES OF AMERICA35 (CRANKCASE FRONT COVER AND FRONT PLATE 71 General ‘The erankeas front cover (6) ut. 71 9 light metal ‘ily eating, It sets the ring goer ins ere {he cana front ol seal andthe ting pointer epi tothe front cover and pote ste ormly e+ feted 10 raplscemant of tale and gate, However, the cover mut always be raved, whenever reroal ‘of crantaate, camshaft or iar goat bso 1 the cover and plate ae rmoved, rela snd eal on ean ‘Specifications Bore damter for il sel (oh tis. 71 ‘ming pointer (10) Diameter of ‘ming pote (10) Front plate) Bore diamter for hycraulle ‘Bump and injection pump ‘ange Removal and Disassembly Clean agin externa. Drain coolant and engine oi, Remove fan, V-belt oulley, generar, thrmorat en ‘necting hese, flange (2) ut. 71 and water pump, ot ‘eserbed under the respective sections Wort 72 1 Studnut 2 Viste oan OTE: On ena Mort, 79 the se 18 str channe (3) cone ie is acued by sud (1) Must. 72 Iocan bonne water pomp, sore the ler ser, Remove be sus out isle stoping to take of he onan heft 2 3 1 — Front pote 2 Seating To remote the font vith “gear nthe ineton ccesaiot36 Cleaning, Inspection and Repair Clan all pan a suitabiesohent. Rema any posible eposis from water channal, water Pump caret, 2d Inspect the trom eover fr corrosion, evacks and stor tion. plan te eanksnatt front sa (3) ut 74, ‘ring (9) ane sper ng (6) whanovr the Crane aver NOTE: Insta te new oles, spacer eng and O-ring ‘nth the front covrin ple, afar to ust. 7a Inspect tron pate for astrton and warpape. Install om front plate, necessary. Check the sw inition pump stad for eheft. Whan Instoling stud um Equi sels or tighten to 10.8 Nem (@mbefa, Tien lack nuts and stow fo ple by bunching in thea. Wen instling the sing pole (10) Must. 71 us Tigi sel, Reassombly and Installation se ses onc gaskets throughout, epise front pat on eenkeste dowel, Inga injection pum, camshaft ad idle ear eter to “Turn for correct meng of timing gs Replace erankoue ‘ront cover on dowel sng, ving rw goskat to ure ug seling, Installation of the front oil seal, crankcase front cover in ploce ‘To remove ol space (6) sip dowel (7) with a ple of plies When mount following points the crankshaft front ol el obarve the 1, Handle ol ele with care and protect agua conta Inaion andor dace, 2. Prior to ssembiy, apply some engine oll to te ‘aalng ips (3) lust. 74. ‘The outer cape of the 3. The sealing tp (3) must be installed towards the ot side 3s shown. Use tcl (6) to ensure comect desth ‘contol anda perpanclulrsat othe rene 4, Place O-Ring {0} onto erankahat agin pinion (2) 5. Ina! dowe! pin (7 (same length os removed pin int space rng (6), observing dimenson 6. Install spueer log on crankshaft, taking care gee its rll pin Inthe ting slot ofthe crankset Careful: Do not damage seating tae, Never stem 0 remove minor danage by pelshing Althoush ii peeferble tis the onto sal with the tron cover in plas ean als be install wit rt ts. 75 {insta the new ol sel using he insaling Yoo roles NOTE: When using the dsl ip sal donot smear arease Dewen dust tp ane ol sag ip Be sum the wal este equaly ints bore and that i ie ‘od with he ajar ace of ha front cover Whenever the front oleae replsed, the ssce ing (12) ilu, 85 on whi thie ‘mal rons, mst so be replaced Indall V.belt ply, generator, water pump, Vata fon 1 —Crankaate 5 Space ring Fillin eg and fl the eoting system 2 Pinion 7 Dowel sin ere 3 “otters 8 Pin protrusion 4 Lrankeste tronteoeer mm= 118) Make a tes run and check for lekage, check engine Bo Somel teal PLTSII7 9-OFing timing ste, and ety, I neesay cces 3104‘CRANKCASE, OIL PAN, FLYWHEEL HOUSING 37 ust 76 General ua to the diferent sake soa number of eylingas, ‘crankeat of the engine differ in eight ar ‘ther dimensions, machines face and mt se ldentea All aching faces on th crnkeaia and the oil pana seat surfaces and, therefor, require careful handing. ‘ral dents will ease rouble which may not be spca fntuntil he egin eranning Due to alert engine applicaon she mala being aps may be loceted by dowel busing oF ate guided Tater In he crankcase witha iaht pros ‘The eankcae (1) sed main bearing caps (35 thr 38) are dllein ene operation Main bearing aps ae ourbeed from 1 to. bepinieg at font of sone so that ty canbe reinstaled in proper postion ane sequence, Incvidualbrorig capsare not supe separa Howover for epsir purposed packages ae avalable containing bering cap with bos end an Instruction NOTE: Repsrs ae rexeite to every second baring ‘ap. ‘The front bering cn snot avaoie for sevice, ‘epare n crankeaee ae ganerly rested to epee: Imane of ssaling pore and leaning of oll end water ‘As 4 gunsral rus, machined facet of the eanksas ‘haul slvays be examined for damaseorior to ease iyo the ergne For carat bushings (11 end 12) lust. 76 rer ost etainer (82), and dor gar (17) rfor 0 the respective ‘tions of ti mania ‘Removal and Disassembly Remove the engine and mount i ona suitable stand to fetta rep work, ccessi0-4